# Patent

## Title
Electrolyte for lithium ion batteries

## Abstract

A non-aqueous electrolyte usable in rechargeable lithium-ion batteries including a solution of LiPF6/carbonate based electrolytes with low concentrations of LiFOP such that the thermal stability is increased compared to a standard lithium battery. A method of making lithium tetrafluorophospahte (LiF4C2O4, LiFOP) including, reacting PF5 with lithium oxalate, recrystallizing DMC/dichloromethane from a 1:1 mixture of to separate LiF4OP from LiPF6 to form a lithium salt. An electric current producing rechargeable Li-ion cell. The rechargeable lithium ion cell includes an anode, a cathode, and a non-aqueous electrolyte comprising a solution of a lithium salt in a non-aqueous organic solvent containing lithium tetrafluorooxalatophosphate (LiPF4(C2O4), LiF4OP).

## Background
PRIORITY INFORMATION
The present application is a continuation application of PCT/US08/56161, filed on Mar. 7, 2008 which claims priority from Provisional Patent Application 60/893,734 filed with the United States Patent and Trademark Office on Mar. 8, 2007.


GOVERNMENT SPONSORSHIP
The present invention was made with U.S. Government support under NSF/CIA (Award No. DMR-0442024) and the US Army Research Laboratory (Contract No. W911 QX-07-C-0026 to Yardney Technical Products). The U.S. Government has certain rights to this invention.


BACKGROUND OF THE PRESENT INVENTION
Lithium ion batteries (LIBs) are one of the most widely used portable power sources. However, loss of power and capacity upon storage or prolonged use especially at elevated temperature (>50° C.) limits the application of LIB for electric vehicle (EV) and hybrid electric vehicle (HEV) applications. The performance degradation is frequently linked to the thermal instability of lithium hexafluorophosphate and the reactions of the electrolyte with the surface of the electrode materials. This has prompted the development of alternative electrolytes for lithium ion batteries.
The most widely utilized lithium salt for lithium ion batteries is lithium hexafluorophosphate (LiPF6). However, LiPF6 has poor thermal and hydrolytic stability and is thus not ideal. One of the most widely investigated “alternative” salts for lithium ion battery electrolytes is lithium bisoxalatoborate (LiB(C2O4)2, LiBOB). Lithium ion batteries containing LiBOB based electrolytes have been reported to operate up to 70° C. with little capacity fade. However, the use of LiBOB has been limited by the poor solubility of LiBOB in common carbonate solvents and the poor performance of LiBOB electrolytes at low temperature. LiBOB based electrolytes have been reported to generate a stable solid electrolyte interface (SEI) on the surface of the anode due to ring-open reactions of the oxalate moiety and the formation of trigonal borates.
SUMMARY OF THE INVENTION
In an effort to develop new salts for lithium ion battery electrolytes, lithium tetrafluorooxalatophosphate (LiPF4(C2O4), LiF4OP) has been designed as a new compound. Upon discovery of this new and potentially interesting lithium salt, a synthetic method for the preparation of LiF4OP was developed.
These and other features and objectives of the present invention will now be described in greater detail with reference to the accompanying drawings, wherein:



BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a 19F, and 31P NMR spectra of LiF4OP electrolyte;
FIG. 2 is a graph of the charge-discharge characteristics of a coin cell containing 1:1 LiPF6/LiF4OP in 1:1:1 EC/DEC/DMC for the first four charge-discharge cycles;
FIG. 3 is a graph of the discharge capacity (Ah) of coin cell containing 1:1 LiPF6/LiF4OP in 1:1:1 EC/DEC/DMC during first four charge-discharge cycles;
FIG. 4 is a graph of the charge-discharge characteristics of coin cell containing 1 M LiPF6 with 2% (wt) LiF4OP in 1:1:1 EC/DEC/DMC for the first four charge-discharge cycles;
FIG. 5 is a graph of the discharge capacity (Ah) of coin cell containing 1 M LiPF6 with 2% (wt) LiF4OP in 1:1:1 EC/DEC/DMC during first four charge-discharge cycles;
FIG. 6 is a graph of the conductivity of a 1:1 mixture of LiPF6/LiF4OP vs LiPF6 in a ternary mixture of carbonate solvents; and
FIG. 7 is a schematic of a lithium salt.



DETAILED DESCRIPTION OF THE INVENTION
Lithium tetrafluoro oxalato phosphate (LiPF4(C2O4)) (as shown in FIG. 7) can be used as a lithium salt in the lithium battery. The salt has a high conductivity and solubility but is more thermally stable than the industry standard LiPF6 which could lead to a longer calendar life performance.
EXPERIMENTAL
Battery grade carbonate solvents were obtained from EM Industries (located in Japan), LiPF6 was obtained from Hashimoto Chemical Corporation in Japan, without further purification. Purity was verified by Nuclear Magnetic Resonance (NMR) spectroscopy. Samples for NMR spectroscopy were prepared in an Ar-filled glove box followed by flame sealing and stored for varying lengths of time at 85° C. NMR analyses were conducted on a JEOL 400 MHz NMR spectrometer. 1H NMR resonances were referenced to EC at 4.51 ppm, 19F NMR resonances were referenced to LiPF6 at 65.0 ppm and 31P NMR resonances were referenced to LiPF6 at −145.0 ppm.
Lithium tetrafluorooxalatophosphate (LiF4OP) was synthesized by the reaction of PF5 gas, generated by heating solid LiPF6 to 200° C., transferred via a slow stream of N2 into a suspension of lithium oxalate in dimethyl carbonate at 25° C. The reaction mixture was allowed to stir at 25° C. for 3 h followed by purification by repeated recrystallization from 1:1 dimethyl carbonate/dichloromethane. An electrolyte composed of 1:1 LiPF6/LiF4OP in 1:1:1 ethylene carbonate (EC)/diethyl carbonate (DEC)/dimethyl carbonate (DMC) was examined in lithium-ion coin cells with LiNi0.8Co0.2O2 and mesocarbon microbead (MCMB) graphite as cathode and anode materials respectively. The cells underwent four formation cycles (C/20 and three C/10).







TABLE 1







19F, 31P and 11B NMR assignments of Lithium hexafluoro phosphate


and lithium tetrafluorooxalatophosphate













19F ppm (mult,
31P ppm
11B



Salts
JP-F or JB-F)
(mult, JP-F)
ppm







LiPF6
65.0 (d, 709)
−145.0
—





(sept, 709)



LiF4OP
79.5 (d-t 776, 52)
−142.2 (t-t
—




62.7 (d-t 748, 52)
776, 748)










Preparation and Investigation of LiF4OP

A 1:1 mixture of LiF4OP and LiPF6 was prepared by the reaction of PF5 with lithium oxalate (See Scheme 1). Repeated recrystallization from a 1:1 mixture of DMC/dichloromethane can be used to remove LiPF6. An investigation of the thermal stability of carbonate solutions of LiF4OP and the use of 1:1 LiPF6/LiF4OP in 1:1:1 EC/DMC/DEC as an electrolyte in lithium ion batteries was conducted. Dissolution of LiF4OP in 1:1:1 EC/DEC/DMC resulted in a clear colorless solution. 19F and 31P NMR spectroscopy confirmed the structure of LiF4OP (FIG. 2). Thermal stability of 1.0 M LiF4OP in EC: DEC: DMC (1:1:1) was investigated by NMR spectroscopy, Storage of the electrolyte at 85° C. for 3 months resulted in a slight yellowing of the solution, likely due to trace impurities, but no evidence for bulk electrolyte decomposition. The 1H, 19F, and 31P NMR spectra of the electrolyte revealed that a low concentration of the lithium fluorophosphate (OPF2(OLi)) was generated during the first 48 hours of storage at 85° C. However, the concentration of OPF2(OLi) did not increase upon storage for 3 months at 85° C. Incorporation of additive concentrations of LiF4OP to LiPF6 based electrolytes was investigated. The addition of 2% (wt) LiF4OP to ternary electrolyte inhibited the thermal decomposition of the electrolyte.




Performance of Lithium-Ion Cells with 1:1 LiPF6/LiF4OP

The effect of LiF4OP on the initial cycling performance of coin cells was examined. The cells were cycled in the following schedule: four formation cycles (one at C/20 followed by three C/10 charge-discharge rate cycles) at 25° C., FIG. 3 is a representative data set of the charge-discharge characteristics of a coin cell containing 1:1 LiPF6/LiF4OP (1 M Li) in EC: DEC: DMC (1:1:1). The data suggested that the LiF4OP electrolyte had good performance in LIB. Compared to cells containing ternary electrolyte, a plateau around 1.9 V was clearly observed during the first cycle due to the reduction of oxalate impurities in LiF4OP. As with previous investigations with LiBOB electrolytes, the size of the 1.9 V plateau was dependent upon the concentration of LiF4OP in LiPF6. Cells containing 1:1 LiPF6/LiF4OP in 1:1:1 EC/DEC/DMC had good reversibility over the first four cycles, FIG. 4, suggested that LiF4OP electrolytes were not detrimental to the lithium intercalation/deintercalation processes. The reversible capacity of cells containing 1:1 LiPF6/LiF4OP in 1:1:1 EC/DEC/DMC was similar to comparable cells containing ternary electrolyte. Addition of 2% (wt) LiF4OP to ternary electrolyte results in shorter 1.9 V plateaus but similar cycling profiles.
A solution of LiPF6/carbonate based electrolytes has a low concentration of LiF4OP when the concentration is about 0.1-5.0% (by wt). This solution when used in a rechargeabole lithium battery has increased thermal stability compared to a standard lithium battery. Whereas a concentration of about 5.0-95.0% (by wt) is considered as a high concentration.
An electric current producing rechargeable Li-ion cell has an anode; a cathode; and a non-aqueous electrolyte. The non-aqueous electrolyte includes a solution of a lithium salt in a non-aqueous organic solvent containing lithium tetrafluorooxalatophosphate (LiPF4(C2O4), LiF4OP). The anode may be a lithium intercalating compound where the said lithium intercalating compound is a carbonaceous material. The cathode may be a lithium intercalating transition metal compound. The lithium intercalating transition metal compound may be selected from the group consisting of LiCoO2; LiNiO2; LiNi1-xCoxO2 where x is 0.3<x<1.0; LiMn2O4; LiV2O5; LiMxN1-xO2, where M and N are transition metals and x has a value between zero and one; LiFePO4; LiCrS2; and LiVS2. The organic solvent is selected from the group consisting of organic carbonates, esters, ethers, glymes, organic nitriles and sulfones as well as mixtures thereof.
In light of the foregoing, it will now be appreciated by those skilled in the art that various changes may be made to the embodiment herein chosen for purposes of disclosure without departing from the inventive concept defined by the appended claims.

## Claims

1. A method of making lithium tetrafluorophosphate (represented by LiPF4C2O4, or LiF4OP) for use as a lithium ion battery electrolyte, said method consisting essentially of the steps of:
heating solid LiPF6 to 200° C. to produce PF5 gas;
reacting the PF5 gas with lithium oxalate; and
recrystallizing from a 1:1 mixture of dimethyl carbonate (DMC)/dichloromethane to separate LiF4OP from LiPF6 to form a lithium salt.

2. The method as claimed in claim 1, wherein said lithium tetrafluorophosphate is lithium tetrafluoro oxalato phosphate (represented by LiPF4C2O4).

3. The method as claimed in claim 1, wherein the LiPF6 is provided in a solution of LiPF6/carbonate based electrolytes with low concentrations of LiFOP of about 0.1-5.0% by wt.

4. The method as claimed in claim 1, wherein the LiPF6 is provided in a solution of LiPF6/carbonate based electrolytes with high concentrations of LiFOP of about 5.0-95.0% by wt.

5. The method as claimed in claim 1, wherein said lithium ion salt is:

6. A method of making lithium tetrafluorophosphate (represented by LiPF4C2O4, or LiF4OP,) for use as a lithium ion battery electrolyte, said method consisting essentially of the steps of:
heating solid LiPF6 to 200° C. to generate a PF5 gas;
reacting the PF5 gas with lithium oxalate to provide a reaction mixture;
stirring the reaction mixture; and
recrystallizing from a 1:1 mixture of dimethyl carbonate/dichloromethane to remove LiPF6 from LiF4OP to form a lithium salt.

7. The method as claimed in claim 6, wherein said steps of stirring the reaction mixture and recrystallizing from the 1:1 mixture of dimethyl carbonate/dichloromethane are repeated.

8. The method as claimed in claim 6, wherein said step of stirring the reaction mixture is performed at a temperature of about 25° C.

9. The method as claimed in claim 6, wherein said method further has the step of transferring the PF5 gas via a stream of N2 into a suspension of lithium oxalate in dimethyl carbonate.

10. The method as claimed in claim 9, wherein said suspension of lithium oxalate in dimethyl carbonate is provided at about 25° C.