Technical Field
[0001] The present invention relates to a garnet-type lithium ion-conducting oxide and an
all-solid-state lithium ion secondary battery containing the garnet-type lithium ion-conducting
oxide.
Background Art
[0002] All-solid-state lithium ion secondary batteries contain solid electrolytes and therefore
are less flammable than lithium ion secondary batteries containing nonaqueous electrolytes.
Proposed examples of the all-solid-state lithium ion secondary batteries include a
battery in which a lithium-lanthanum-titanium composite oxide is used as a solid electrolyte
is (Patent Document 1) and a battery in which a Li
2S-P
2S
3 composition is used as a solid electrolyte (Patent Document 2). These batteries have
not been in practical use. One of reasons for this is an issue relating to solid electrolytes.
The solid electrolytes need to have three major properties: high lithium ion conductivity,
high chemical stability, and a wide potential window. However, any solid electrolyte
having such properties has not been discovered.
[0003] Garnet-type oxides have advantages such as high chemical stability and a wide potential
window and therefore are candidates for solid electrolytes. However, the garnet-type
oxides have disadvantages such as low conductivity. Weppner has recently reported
that a garnet-type oxide, Li
7La
3Zr
2O
12, synthesized by a solid phase reaction has a conductivity of 1.9 × 10
-4 to 2.3 × 10
-4 Scm
-1 at 25°C and an activation energy of 0.34 eV (Non-patent Document).
[0006] DE 10 2007 030604 A1 relates to the use of a solid ion conductor having a garnet-like crystal structure
as a coating for an electrode/protective layer in front of an electrode.
[0008] EP 2 099 086 A1 relates to a method for producing a solid electrolyte structure, comprising a precursor
preparation process of preparing a structure precursor and a structure production
process of sintering the structure precursor to produce the solid electrolyte structure,
wherein the precursor preparation process comprises the steps of depositing a fine
particle aggregate layer containing aggregated fine particles of a solid electrolyte
and depositing another fine particle aggregate layer containing polymer particles
and aggregated fine particles of a solid electrolyte, and the structure production
process comprises the step of sintering the structure precursor, thereby removing
the polymer particles to produce the solid electrolyte structure having a porous solid
electrolyte portion and a dense solid electrolyte portion in an integrated state.
[0009] EP 2 159 867 A1 discloses a ceramic material containing Li, La, Zr, O and Al, as well as a process
for producing a ceramic material, comprising a first firing step of firing a starting
material containing a Li component, La component and Zr component to obtain a primary
firing powder for ceramic synthesis containing Li, La, Zr and O, and a second firing
step of firing the primary firing powder obtained in the first firing step to synthesize
a ceramic having a garnet-type crystal structure or a garnet-like crystal structure
containing Li, La, Zr and O, wherein a ceramic material having the garnet-type crystal
structure or the garnet-like crystal structure and containing Al is produced by performing
either or both of the first firing step and second firing step in the presence of
a compound containing Al.
Disclosure of the Invention
[0010] There is no significant difference in conductivity between Li
7La
3Zr
2O
12 and lithium ion-conducting oxides other than garnet-type lithium ion-conducting oxides
although the conductivity of Li
7La
3Zr
2O
12 is greater than that of conventional garnet-type oxides. The conductivity of a glass
ceramic, Li
1.5Al
0.5Ge
1.5(PO
4)
3 (hereinafter referred to as LAGP), is about 7.0 × 10
-4 Scm
-1 and is substantially equal to that of Li
7La
3Zr
2O
12. The conductivity of a glass ceramic, Li
1+XTi
2Si
XP
3-XO
12·AlPO
4 (hereinafter referred to as an Ohara electrolyte), is about 1 × 10
-3 Scm
-1; hence, the conductivity of the Ohara electrolyte is about one order of magnitude
less than that of Li
7La
3Zr
2O
12. Therefore, the development of a garnet-type oxide with higher conductivity is expected.
The LAGP is reduced at 0.5 V or less (versus lithium ions) and the Ohara electrolyte
is reduced at 1.5 V or less (versus lithium ions) ; hence, the LAGP and the Ohara
electrolyte do not meet a potential window required for a solid electrolyte for secondary
batteries.
[0011] The present invention has been made to solve such a problem. It is an object of the
present invention to provide a garnet-type oxide having high chemical stability, a
wide potential window, and high lithium ion conductivity. It is another object of
the present invention to provide an all-solid-state lithium ion secondary battery
containing such a garnet-type oxide.
[0012] In order to achieve the objects, the inventors have investigated the composition
of a garnet-type oxide, Li
7La
3Zr
2O
12. The inventors have found that the garnet-type oxide modified by substituting an
appropriate amount of Nb for Zr sites therein has a lithium ion conductivity exceeding
that of Li
7La
3Zr
2O
12 and also have found that the garnet-type oxide is useful as a solid electrolyte for
all-solid-state lithium ion secondary batteries. This has led to the completion of
the present invention.
[0013] A first garnet-type lithium ion-conducting oxide according to the present invention
has a garnet-like structure and is represented by the formula Li
5+XLa
3 (Zr
X, A
2-X) O
12, wherein A is at least one selected from the group consisting of Sc, Ti, V, Y, Nb,
Hf, Ta, Si, Ga, Ge, and Sn and X satisfies the inequality 1.4 ≤ X < 2.
[0014] A second garnet-type lithium ion-conducting oxide according to the present invention
is one, obtained by substituting an element having an ionic radius different from
that of Zr for Zr sites in an garnet-type lithium ion-conducting oxide represented
by the formula Li
7La
3Zr
2O
12, having an X-ray diffraction (XRD) pattern with a (024) diffraction peak having a
normalized intensity of 9.2 or more as normalized on the basis of the intensity of
a (220) diffraction peak.
[0015] The first and second garnet-type lithium ion-conducting oxides have chemical stability
and potential window substantially equivalent to those of a conventional garnet-type
oxide, Li
7La
3Zr
2O
12, and also have higher lithium ion conductivity and a smaller rate of change in lithium
ion conductivity with temperature as compared with the garnet-type oxide. The reason
for the above is probably as described below. It is known that a garnet-like structure
contains tetracoordinated lithium ions each forming a tetrahedron together with oxygen
ions located at the vertices of the tetrahedron and hexacoordinated lithium ions each
forming an octahedron together with oxygen ions located at the vertices of the octahedron.
In the garnet-like structure, the atomic coordinates of oxygen ions surrounding lithium
ions are varied by substituting an element (for example, A described above) having
an ionic radius different from that of Zr for Zr sites. Distances between the oxygen
ions surrounding the lithium ions are increased by adjusting the amount of the element
used; thereby allowing the lithium ions to migrate readily. This probably leads to
an increase in lithium ion conductivity and a reduction in the rate of change in conductivity
with temperature because of a reduction in activation energy.
[0016] An all-solid-state lithium ion secondary battery according to the present invention
has a configuration in which a solid electrolyte layer is sandwiched between a positive
electrode containing a positive electrode active material capable of occluding and
releasing lithium ions and a negative electrode containing a negative electrode active
material capable of releasing and occluding lithium ions. The solid electrolyte layer
is made of the first or second garnet-type lithium ion-conducting oxide.
[0017] An all-solid-state lithium ion secondary battery according to the present invention
contain a novel garnet-type oxide serving as a solid electrolyte. The novel garnet-type
oxide has chemical stability and potential window substantially equivalent to those
of a conventional garnet-type oxide, Li
7La
3Zr
2O
12, and also has higher lithium ion conductivity and a smaller rate of change in lithium
ion conductivity with temperature as compared with the garnet-type oxide. Therefore,
the all-solid-state lithium ion secondary battery containing the novel garnet-type
oxide has good battery properties and therefore is expected to be applied particularly
for vehicles required to have high power.
Brief Description of Drawings
[0018]
Fig. 1 is a graph showing the XRD patterns of samples of Examples 1, 3, 5, and 7;
Fig. 2 is a graph showing the X-value dependence of lattice parameters of samples
of Examples 1 to 3 and 5 to 7;
Fig. 3 is a graph showing the X-value dependence of the conductivity of samples of
Examples 1 to 7;
Fig. 4 is an illustration of portions of the crystal structure of a garnet-type oxide;
Fig. 5A is an illustration of the whole crystal structure of the garnet-type oxide;
Fig. 5B is an illustration showing LiO6 (II) octahedrons exposed from the crystal structure;
Fig. 6A is a graph showing the X-value dependence of sides a and b of a triangle formed by oxygen ions in each of LiO4 (I) tetrahedrons of samples of Examples 1, 3, and 5 to 7;
Fig. 6B is a graph showing the X-value dependence of the area of the triangle;
Fig. 7 is a graph showing the X-value dependence of the normalized intensity of each
of diffraction peaks of samples of Examples 1 to 3, 5, and 7, the normalized intensity
being determined by normalizing the intensity of each diffraction peak on the basis
of the intensity of the (220) diffraction peak of a corresponding one of the samples;
Fig. 8 is a graph showing the X-value dependence of the normalized intensity of each
of diffraction peaks of samples of Examples 1, 3, and 5 to 7, the normalized intensity
being determined by normalizing the intensity of each diffraction peak on the basis
of the intensity of the (024) diffraction peak of a corresponding one of the samples;
Fig. 9 is a graph showing the Arrhenius plots of samples of Examples 1 to 7;
Fig. 10 is a graph showing the X-value dependence of the activation energy of each
of samples of Examples 1 to 7;
Fig. 11 is a graph showing the chemical stability of a sample of Example 5, the sample
being tested at room temperature in air;
Fig. 12 is a graph showing results obtained by measuring the potential window of the
sample of Example 5;
Fig. 13A is a front view of a pellet having a positive electrode active material layer;
Fig. 13B is a right side view of the pellet;
Fig. 14 is a sectional view of an all-solid-state lithium ion secondary battery;
Fig. 15 is a graph showing charge-discharge properties of the all-solid-state lithium
ion secondary battery;
Fig. 16 is a graph showing the capacity of the all-solid-state lithium ion secondary
battery at each cycle;
Fig. 17 is an illustration showing an example of the structure of the all-solid-state
lithium ion secondary battery;
Fig. 18 is an illustration showing an example of the structure of the all-solid-state
lithium ion secondary battery; and
Fig. 19 is an illustration showing an exemplary technique for preparing the all-solid-state
lithium ion secondary battery.
Preferred Embodiments of the Invention
[0019] A first garnet-type lithium ion-conducting oxide according to the present invention
has a garnet-like structure and is represented by the formula Li
5+XLa
3 (Zr
X, A
2-X) O
12, wherein A is as described above and X satisfies the inequality 1.4 ≤ X < 2. Since
X satisfies the inequality 1.4 ≤ X <2, the first garnet-type lithium ion-conducting
oxide has higher lithium ion conductivity and lower activation energy as compared
with a known garnet-type lithium ion-conducting oxide, Li
7La
3Zr
2O
12 (that is, X = 2). When A is, for example, Nb, the first garnet-type lithium ion-conducting
oxide has a lithium ion conductivity of 2.5 × 10
-4 Scm
-1 or more and an activation energy of 0.34 eV or less. Therefore, the use of the first
garnet-type lithium ion-conducting oxide in an all-solid-state lithium ion secondary
battery allows lithium ions to be readily conducted; hence, the all-solid-state lithium
ion secondary battery has low electrolyte resistance and high output. Since the activation
energy of the first garnet-type lithium ion-conducting oxide, that is, the rate of
change in conductivity with temperature thereof is small, the output of the all-solid-state
lithium ion secondary battery is stable. The value X preferably satisfies the inequality
1.6 ≤ X ≤ 1.95 because the first garnet-type lithium ion-conducting oxide has higher
lithium ion conductivity and lower activation energy. The value X more preferably
satisfies the inequality 1.65 ≤ X ≤ 1.9 because the first garnet-type lithium ion-conducting
oxide has a substantially maximal lithium ion conductivity and a substantially minimal
activation energy. A is preferably Nb or Ta, which has an ionic radius substantially
equal to that of Nb.
[0020] A second garnet-type lithium ion-conducting oxide according to the present invention
is one, obtained by substituting an element having an ionic radius different from
that of Zr for Zr sites in an garnet-type lithium ion-conducting oxide represented
by the formula Li
7La
3Zr
2O
12, having an XRD pattern with a (024) diffraction peak having a normalized intensity
of 9.2 or more as normalized on the basis of the intensity of a (220) diffraction
peak, the element being at least one selected from the group consisting of Sc, Ti,
V, Y, Nb, Hf, Ta, Si, Ga, and Ge, and Sn. Since the normalized intensity of the (024)
diffraction peak is 9.2 or more, a triangle formed by oxygen ions in a LiO
4 (I) tetrahedron is close to an equilateral triangle and has a large area; hence,
the second garnet-type lithium ion-conducting oxide has higher lithium ion conductivity
and lower activation energy as compared with the known garnet-type lithium ion-conducting
oxide having the formula Li
7La
3Zr
2O
12 (that is, X = 2). When A is, for example, Nb, the second garnet-type lithium ion-conducting
oxide has a lithium ion conductivity of 2.5 × 10
-4 Scm
-1 or more and an activation energy of 0.34 eV or less. Therefore, the use of the second
garnet-type lithium ion-conducting oxide in an all-solid-state lithium ion secondary
battery allows lithium ions to be readily conducted; hence, the all-solid-state lithium
ion secondary battery has high output. Since the activation energy of the second garnet-type
lithium ion-conducting oxide, that is, the rate of change in conductivity with temperature
thereof is small, the output of the all-solid-state lithium ion secondary battery
is stable. The normalized intensity of the (024) diffraction peak is preferably 10.0
or more because the second garnet-type lithium ion-conducting oxide has higher lithium
ion conductivity and lower activation energy. The normalized intensity of the (024)
diffraction peak is more preferably 10.2 or more because the second garnet-type lithium
ion-conducting oxide has a substantially maximal lithium ion conductivity and a substantially
minimal activation energy. A is preferably Nb or Ta, which has an ionic radius substantially
equal to that of Nb.
[0021] An exemplary method for producing the first or second garnet-type lithium ion-conducting
oxide is described below. The method includes (1) a first mixing step of mixing inorganic
materials including a lithium compound, the inorganic materials being changed in state
by calcination and used as raw materials; (2) a first calcining step of calcining
the mixed inorganic materials at a predetermined calcining temperature to change the
state of the inorganic materials; (3) a second mixing step of mixing the inorganic
materials with a predetermined amount of another inorganic material; (4) a second
calcining step of calcining the inorganic materials, calcined in the second mixing
step, at a predetermined calcining temperature; and (5) a forming/calcining step of
forming the inorganic materials calcined in the second calcining step into a compact
and calcining the compact at a forming/calcining temperature. These steps are described
below in detail.
(1) First mixing step
[0022] In this step, the inorganic materials, which are changed in state by calcination
at a predetermined temperature, are mixed together. In particular, the inorganic materials
are pulverized and mixed together so as to form a composition represented by the formula
Li
5+XLa
3(Zr
X, A
2-
X)O
12, wherein A is as described above and X satisfies the inequality 1.4 ≤ X < 2. Examples
of the inorganic materials include carbonates, sulfonates, nitrates, oxalates, chlorides,
hydroxides, and oxides of elements contained in the composition. In particular, the
carbonates and hydroxides are preferred because carbon dioxide and water produced
by the thermally decomposition of the carbonates and hydroxides, respectively, are
relatively readily treated. For example, Li
2CO
3, La (OH)
3, ZrO
2, and A
2O
3 are preferably used, wherein A is as described above. The term "changed in state"
as used herein may mean that gas is produced or a predetermined phase transition occurs.
The inorganic materials, which are raw materials, are preferably mixed at a mixing
ratio so as to form the target composition. The inorganic materials may be pulverized
and mixed by a dry process without using any solvent or may be pulverized and mixed
by a wet process. The inorganic materials are preferably pulverized and mixed in a
solvent by such a wet process in view of an increase in mixing performance. For example,
a planetary mill, an attritor, a ball mill, or the like can be used to mix the inorganic
materials. The solvent is preferably one that hardly dissolves Li and is more preferably
an organic solvent such as ethanol. The mixing time of the inorganic materials depends
on the amount thereof and may be, for example, two to eight hours.
(2) First calcining step
[0023] In this step, the inorganic materials mixed in the first mixing step are calcined
at a predetermined calcining temperature (hereinafter referred to as a first temperature)
that is higher than or equal to a predetermined temperature at which the inorganic
materials are changed in state and is lower than the forming/calcining temperature.
The predetermined calcining temperature is higher than or equal to a temperature at
which Li
2CO
3 is decomposed when the inorganic materials include this carbonate. This can suppress
a reduction in density due to the production of gas by thermal decomposition in the
forming/calcining step. The first temperature is preferably 900°C to 1,150°C. The
calcining temperature of the inorganic materials can be empirically determined within
a range where the inorganic materials are sufficiently changed in state and the evaporation
of a readily volatile component (hereinafter also referred to as a volatile component)
such as lithium can be prevented.
(3) Second mixing step
[0024] In this step, the inorganic material is added to the inorganic materials (hereinafter
also referred to as first materials) calcined in the first calcining step and these
inorganic materials are mixed together, the amount of the added inorganic material
being determined depending on conditions for calcining the inorganic materials. A
principal object of this step is to correct changes in composition due to evaporation
in each calcining step. An example of the added inorganic material is an inorganic
compound, such as Li
2CO
3, containing the volatile component or the like. The amount of the added inorganic
material can be empirically determined depending on conditions of the first and second
calcining steps and the forming/calcining step. The amount of the added inorganic
material may be determined depending changes in composition. The type of the added
inorganic material, a process for mixing the added inorganic material with the inorganic
materials, and the mixing time of the added inorganic material and the inorganic materials
may be as described in the first mixing step. In the second mixing step, the type
of the added inorganic material, the process for mixing the added inorganic material
with the inorganic materials, and the mixing time of the added inorganic material
and the inorganic materials may be the same as or different from those described in
the first mixing step. In the second mixing step, Li is preferably added to the inorganic
materials such that the amount of Li added thereto is 4 to 20 atomic percent of the
amount of Li in the inorganic materials.
(4) Second calcining step
[0025] In this step, the inorganic materials (the first materials) mixed with the added
inorganic material are calcined at a calcining temperature (hereinafter referred to
as a second temperature) that is higher than or equal to a predetermined temperature
at which the inorganic materials are changed in state and is lower than the forming/calcining
temperature. A principal object of this step is to change the state of the added inorganic
material. The second calcining step may be performed under substantially the same
conditions as those of the first calcining step. The second calcining step is preferably
performed at a temperature that is higher than or equal to the predetermined temperature
at which the inorganic materials are changed in state and is lower than equal to the
calcining temperature of the first calcining step. This prevents the calcined inorganic
materials from being solidified; hence, the inorganic materials calcined in the forming/calcining
step need not be pulverized. Since the amount of the inorganic material changed in
state in the second calcining step is far less than that in the first calcining step,
the calcining temperature in the second calcining step may be short. Since the second
calcining step is performed, a reduction in density due to the change in state of
the inorganic material added to suppress changes in composition can be suppressed
in the forming/calcining step.
(5) Forming/calcining step
[0026] In this step, the inorganic materials (hereinafter also referred to as second materials)
calcined in the second calcining step are formed into the compact and the compact
is calcined at the forming/calcining temperature, which is higher than the calcining
temperature. In the forming/calcining step, it is preferred that the second materials
be not pulverized in a solvent in advance of the formation of the compact. This can
prevent the volatile component, which is evaporated in the forming/calcining step
and is excessively contained in the second materials, from being changed in state
due to the contact of the volatile component with such a solvent; hence, a reduction
in density due to the change in state of the inorganic materials can be securely suppressed.
When the inorganic materials include, for example, Li
2CO
3, Li
2O produced from an excessive amount of Li
2CO
3 in the second calcining step can be prevented from being converted into LiOH or Li
2CO
3. In the case of mixing the inorganic materials in a solvent in the first or second
mixing step, it is preferred that the inorganic materials be not mixed in any solvent
in advance of the forming/calcining step. Since the second materials are calcined
twice subsequently to the second calcining step and therefore are hardly solidified
or fixed, the second materials can be relatively readily formed into the compact by
simple breaking. The compact can be formed so as to have an arbitrary shape by subjecting
the second materials to, for example, cold isotropic pressing (CIP), hot isotropic
pressing (HIP), molding, hot pressing, or the like.
[0027] According to the method, an empirically determined amount of the inorganic material
is added to the inorganic materials calcined in the first calcining step, the inorganic
materials and the added inorganic material are re-calcined and then formed into the
compact, and the compact is calcined. Therefore, a change in volume due to the change
in state of the inorganic materials can be reduced and changes in composition can
be accurately suppressed. A method for producing the first or second garnet-type lithium
ion-conducting oxide according to the present invention is not limited to this one
and the first or second garnet-type lithium ion-conducting oxide may be produced by
another method.
[0028] An all-solid-state lithium ion secondary battery according to the present invention
has a configuration in which a solid electrolyte layer is sandwiched between a positive
electrode containing a positive electrode active material capable of occluding and
releasing lithium ions and a negative electrode containing a negative electrode active
material capable of releasing and occluding lithium ions. The solid electrolyte layer
is made of the first or second garnet-type lithium ion-conducting oxide.
[0029] In the all-solid-state lithium ion secondary battery, a polymer electrolyte layer
may be disposed between the solid electrolyte layer and the positive or negative electrode.
This allows the adhesion between the solid electrolyte layer and the positive or negative
electrode to be enhanced; hence, good battery properties are achieved.
[0030] In the all-solid-state lithium ion secondary battery, the positive electrode active
material, which is contained in the positive electrode, may be a sulfide containing
a transition metal element or an oxide containing lithium and a transition metal element.
Examples of the positive electrode active material include transition metal sulfides
such as TiS
2, TiS
3, MoS
3, and FeS
2; lithium-manganese composite oxides such as LiMnO
2 and LiMn
2O
4; lithium-cobalt composite oxides such as LiCoO
2; lithium-nickel composite oxides such as LiNiO
2; lithium-manganese-cobalt composite oxides such as LiMnCoO
4; lithium-iron composite oxides such as LiFeO
2; lithium-iron-phosphorus composite oxides such as LiFePO
4; lithium-vanadium composite oxides such as LiV
2O
4; and transition metal oxides such as V
2O
5.
[0031] In the all-solid-state lithium ion secondary battery, examples of the negative electrode
active material, which is contained in the negative electrode, include metallic lithium,
carbonaceous materials capable of releasing and occluding lithium ions, lithium-containing
alloys such as Li-Al and Li-Zn, indium-containing alloys such as In-Sb and Cu-In-Sn,
oxides such as Li
4Ti
5O
12 and WO
2, lanthanum-nickel compounds such as La
3Ni
2Sn
7, and conductive polymers. The carbonaceous materials are preferred in view of safety.
The carbonaceous materials are not particularly limited. Examples of the carbonaceous
materials include cokes, glassy carbons, graphites, non-graphitizable carbons, pyrolytic
carbons, and carbon fibers. In particular, the negative electrode active material
is preferably graphite such as synthetic or natural graphite because such graphite
has an operating potential close to that of metallic lithium, charge and discharge
can be performed at a high operating voltage, self-discharge can be suppressed in
the case of using a lithium salt as an electrolyte salt, and irreversible capacity
can be reduced during charge.
[0032] In the all-solid-state lithium ion secondary battery, a process for preparing the
positive or negative electrode is not particularly limited and a vapor or solid phase
process can be used to prepare the positive or negative electrode. Examples of the
vapor phase process include pulse laser deposition (PLD), sputtering, vapor deposition,
and chemical vapor deposition (CVD) including metal-organic chemical vapor deposition
(MOCVD). Examples of the solid phase process include a sintering process, a sol-gel
process, a doctor blade process, a screen printing process, a slurry casting process,
and powder pressing. The following solvent can be used to prepare slurry by a doctor
blade process or a similar process: an aromatic hydrocarbon solvent such as toluene
or xylene or an alcoholic solvent such as ethanol or propanol. When the slurry contains
a resin binder, the resin binder may be, for example, a polyvinyl resin. In the case
of manufacturing the all-solid-state lithium ion secondary battery by powder pressing,
all of the positive electrode active material, the negative electrode active material,
and the solid electrolyte may be powdery. Alternatively, the solid electrolyte may
be solid and the positive and negative electrode active materials may be powdery.
Alternatively, the solid electrolyte may be powdery and the positive and negative
electrode active materials may be solid.
[0033] The all-solid-state lithium ion secondary battery is not particularly limited in
shape and may have a coin shape, a button shape, a sheet shape, a multilayer shape,
a cylindrical shape, a flat shape, a rectangular shape, or another shape. Those identical
to the all-solid-state lithium ion secondary battery may be connected to each other
in series so as to form a power supply for electric vehicles. Examples of the electric
vehicles include battery electric vehicles powered by batteries only, hybrid electric
vehicles powered by internal canbustion engines and motors, and fuel-cell electric
vehicles powered by fuel cells.
[0034] The all-solid-state lithium ion secondary battery is not particularly limited in
shape and may have a structure shown in Fig. 17 or 18. The all-solid-state lithium
ion secondary battery 20 includes the solid electrolyte layer 10, which is made of
the first or second garnet-type oxide, the positive electrode 12, which is disposed
on a surface of the solid electrolyte layer 10, and the negative electrode 14, which
is disposed on another surface of the solid electrolyte layer 10, as shown in Fig.
17. The positive electrode 12 includes a positive electrode active material layer
12a containing the positive electrode active material and a positive electrode current
collector 12b in contact with the positive electrode active material layer 12a. The
negative electrode 14 includes a negative electrode active material layer 14a containing
the negative electrode active material and a negative electrode current collector
14b in contact with the negative electrode active material layer 14a. The all-solid-state
lithium ion secondary battery 20 may be manufactured by a vapor phase process, a solid
phase process, or a cambination of a vapor phase process and a solid phase process.
The solid electrolyte layer 10 is formed so as to have a block shape. The positive
electrode 12 and the negative electrode 14 are formed on surfaces of the solid electrolyte
layer 10 by a vapor phase process, a solid phase process, or a combination of a vapor
phase process and a solid phase process. Alternatively, the following members may
be deposited on the negative electrode current collector 14b in this order by a vapor
phase process, a solid phase process, or a combination of a vapor phase process and
a solid phase process: the negative electrode active material layer 14a, the solid
electrolyte layer 10, the positive electrode active material layer 12a, and the positive
electrode current collector 12b. Alternatively, as shown in Fig. 19, the negative
electrode current collector 14b is provided in a cylindrical insulating vessel 30;
a powder of the negative electrode active material, a powder of the solid electrolyte,
and a powder of the positive electrode active material are provided on the negative
electrode current collector 14b in that order; the positive electrode current collector
12b is provided on the negative electrode active material powder; and the positive
and negative electrode current collectors 12b and 14b may be pressed so as to approach
each other. The all-solid-state lithium ion secondary battery 20 may further include
a first polymer electrolyte layer 16 and a second polymer electrolyte layer 18 in
addition to the solid electrolyte layer 10, the positive electrode 12, and the negative
electrode 14 as shown in Fig. 18, the first polymer electrolyte layer 16 being disposed
above a surface of the solid electrolyte layer 10 with the positive electrode 12 disposed
therebetween, the second polymer electrolyte layer 18 being disposed above a surface
of the solid electrolyte layer 10 with the negative electrode 14 disposed therebetween.
The positive electrode 12 includes the positive electrode active material layer 12a
and the positive electrode current collector 12b as described above. The negative
electrode 14 includes the negative electrode active material layer 14a and the negative
electrode current collector 14b as described above. The all-solid-state lithium ion
secondary battery 20 may be manufactured in such a manner that the positive electrode
active material layer 12a is deposited on a surface of the positive electrode current
collector 12b, the negative electrode active material layer 14a is deposited on a
surface of the negative electrode current collector 14b, a gelled polymer electrolyte
is applied to the positive electrode active material layer 12a and the negative electrode
active material layer 14a, and the solid electrolyte layer 10 is sandwiched between
the positive electrode active material layer 12a and the negative electrode active
material layer 14a. The all-solid-state lithium ion secondary battery 20 may include
both or one of the first and second polymer electrolyte layers 16 and 18.
Examples
[Preparation of garnet-type oxides]
[0035] Garnet-type oxides, Li
5+xLa
3(Zr
x, Nb
2-x)O
12 (X = 0-2), were synthesized from the following starting materials: Li
2CO
3, La(OH)
3, ZrO
2, and Nb
2O
3. In Examples 1 to 7, X was equal to 0, 1.0, 1. 5, 1.625, 1.75, 1.875, or 2.0 (see
Table 1). The starting materials were weighed so as to yield a stoichiometric ratio.
The weighed starting materials were pulverized and mixed in ethanol in a planetary
ball mill containing zirconium balls at 300 rpm for one hour (a first mixing step).
A powder of the mixed starting materials was separated from the zirconium balls and
ethanol and then calcined in an Al
2O
3 crucible at 950°C for ten hours under an air atmosphere (a first calcining step).
In order to compensate for the loss of Li during sintering, Li
2CO
3 was excessively added to the calcined powder such that the amount of added Li
2CO
3 was ten atomic percent of the amount of Li in the composition represented by the
formula Li
5+xLa
3 (Zr
x, Nb
2-x)O
12 (X = 0-2). The calcined powder and Li
2CO
3 were mixed in ethanol in a planetary ball mill containing zirconium balls at 300
rpm for one hour (a second mixing step). The obtained mixture was calcined at 950°C
for ten hours in an air atmosphere (a second calcining step). The resulting mixture
was formed into a compact, which was then calcined at 1200°C for 36 hours in an air
atmosphere (a forming/firing step). Samples were prepared by this procedure in Examples
1 to 7. Examples 3 to 6 correspond to examples of the present invention and Examples
1, 2, and 7 correspond to comparative examples.
Table 1
| Example 1 |
X=0 |
Li5La3Nb2O12 |
| Example 2 |
X=1.0 |
Li6La3(Zr1' Nb1)O12 |
| Example 3 |
X=1.5 |
Li6.5La3(Zr1.5' Nb0.5)O12 |
| Example 4 |
X=1.625 |
Li6.625La3(Zr1.625' Nb0.375)O12 |
| Example 5 |
X=1.75 |
Li6.75La3(Zr1.75' Nb0.25)O12 |
| Example 6 |
X=1.875 |
Li6.875La3(Zr1.875' Nb0.125)12 |
| Example 7 |
X=2.0 |
Li7La3Zr2O12 |
[Measurement of properties of garnet-type oxides and measurement results]
1. Relative density
[0036] The measurement density of each sample was calculated in such a manner that the sample
was dried, measured for weight with an electronic balance, and measured for size with
a vernier caliper and the weight of the sample was divided by the volume thereof.
The relative density, in percent, of the sample was determined in such a manner that
the theoretical density of the sample was calculated, the measurement density of the
sample was divided by the theoretical density thereof, and the quotient was multiplied
by 100. In Examples 1 to 7, the samples had had a relative density of 88% to 92%.
2. Phase and lattice parameters
[0037] The phase and lattice parameters of each sample were determined from the XRD measurements
thereof. The XRD of a powder of the sample was measured with an X-ray diffractometer,
D8 Advance, available from Bruker under the following conditions: CuKα, 2θ = 10° to
120°, and 0.01° step/sec. Obtained data was subjected to crystal structure analysis
with a crystal structure analysis program, Rietan-2000 (
Mater. Sci. Forum, (2000), pp. 321-324, 198). Fig. 1 shows the XRD patterns of the samples of Examples 1, 3, 5, and 7, that is,
Li
5+xLa
3 (Zr
x, Nb
2-x)O
12 (X = 0, 1.5, 1.75, or 2). As is clear from Fig. 1, these samples contain no impurities
and have a single phase. Fig. 2 shows the X-value dependence of a lattice parameter
determined from the XRD pattern of each of the samples of Examples 1 to 3 and 5 to
7. As is clear from Fig. 2, an increase in the percentage of Zr increases the lattice
parameter. This is because the radius (r
Zr4+ = 0.79 Å) of a Zr
4+ ion is larger than the radius (r
Nb5+ = 0.69 Å) of an Nb
5+ ion.. Since the lattice parameter varies continuously, Nb is considered to be substituted
for a Zr site (a complete solid solution is considered to be available).
3. Conductivity
[0038] The resistance of each sample was determined from a circular arc of a Nyquist plot
obtained with an AC impedance analyzer in a constant-temperature bath at a frequency
of 0.1 Hz to 1 MHz and an amplitude voltage of 100 mV. The conductivity of the sample
was calculated from the resistance thereof. A blocking electrode used to measure the
resistance of the sample with the AC impedance analyzer was an Au electrode. The Au
electrode was formed in such a manner that an Au paste was applied to the sample and
then baked at 850°C for 30 minute. Fig. 3 shows the X-value dependence of the conductivity
of the samples of Examples 1 to 7, that is, Li
5+xLa
3(Zr
x, Nb
2-x)O
12 (X = 0-2) at 25°C. As is clear from Fig. 3, the conductivity is greater than that
of known Li
7La
3Zr
2O
12 (that is, X = 2, Example 7), is far greater than that of the sample of Example 7,
and is substantially maximal (6 x 10
-4 Scm
-1) when X satisfies the inequality 1.4 ≤ X < 2, the inequality 1.6 ≤ X ≤ 1.95, and
the inequality 1.65 ≤ X ≤ 1.9, respectively. Since the samples have a relative density
of 88% to 92% as described above in Item 1, the reason why the conductivity varies
depending on X is considered to be not due to the influence of density.
[0039] The reason why the conductivity is increased by the addition of an appropriate amount
of niobium is described below. The crystal structure of a garnet-type oxide includes
LiO
4 (I) tetrahedrons each consisting of a lithium ion and four oxygen ions coordinated
thereto, LiO
6 (II) octahedrons each consisting of a lithium ion and six oxygen ions coordinated
thereto, LaO
8 dodecahedrons each consisting of a lanthanum ion and eight oxygen ions coordinated
thereto, and ZrO
6 octahedrons each consisting of a zirconium ion and six oxygen ions coordinated thereto
as shown in Fig. 4. Fig. 5A shows the whole crystal structure thereof. In the crystal
structure shown in Fig. 5A, each LiO
6 (II) octahedron is surrounded by the ZrO
6 octahedrons and the LaO
8 dodecahedrons and therefore cannot be seen. Fig. 5B shows the LiO
6 (II) octahedrons exposed by removing the LaO
8 dodecahedrons from the crystal structure shown in Fig. 5A. Hexacoordinated lithium
ions are each surrounded by six oxygen ions, three lanthanum ions, and two zirconium
ions and are not probably involved in conductivity. Tetracoordinated lithium ions
each form a tetrahedron together with oxygen ions located at the vertices of the tetrahedron.
Fig. 6 shows the structural change of a LiO
4 (I) tetrahedron determined by Rietveld profile analysis. The number of distances
between oxygen ions forming the LiO
4 (I) tetrahedron is two. In the LiO
4 (I) tetrahedron, two long sides are represented by a and a short side is represented
by b. As shown in Fig. 6A, the length of the long sides a is substantially constant
independently of the substitution amount of Nb and the length of the short side b
is increased by substituting an appropriate amount of Nb. That is, the substitution
of an appropriate amount of Nb allows a triangle formed by oxygen ions to be close
to an equilateral triangle and to be increased in area (see Fig. 6B). This suggests
that the substitution of an appropriate amount of Nb for Zr optimizes structures (triangles
formed by oxygen ions) around conducting lithium ions and allows the lithium ions
to migrate readily. An element substituted for Zr may be, for example, Sc, Ti, V,
Y, Hf, Ta, or the like in addition to Nb because a similar structural change can be
expected and therefore a similar advantage can be achieved.
[0040] The intensity of XRD peaks varies depending on the structure or a LiO
4 (I) tetrahedron. Triangles forming the LiO
4 (I) tetrahedron are varied by substituting Nb for Zr sites as described above and
therefore the intensity ratio of the XRD peaks varies. Fig. 7 shows the X-value dependence
of the normalized intensity of each of diffraction peaks of the samples of Examples
1 to 3, 5, and 7, the normalized intensity being determined by normalizing the intensity
of each diffraction peak on the basis of the intensity of the (220) diffraction peak
of a corresponding one of the samples. The normalized intensity of the (024) diffraction
peak, which is typical, of each sample is noted (see Fig. 8). The normalized intensity
of the (024) diffraction peak is 9.2 or more when the inequality 1.4 ≤ X < 2 holds
and therefore the conductivity is greater than that of known Li
7La
3Zr
2O
12 (that is, X = 2, Example 7). The normalized intensity of the (024) diffraction peak
is 10.0 or more when the inequality 1.6 ≤ X ≤ 1.95 holds and therefore the conductivity
is far greater. The normalized intensity of the (024) diffraction peak is 10.2 or
more when the inequality 1.65 ≤ X ≤ 1.9 holds and therefore the conductivity is substantially
maximal.
4. Activation energy (Ea)
[0041] The activation energy (Ea) of each sample was determined from the slope of an Arrhenius
plot using the Arrhenius equation σ = A exp(-Ea/kT), wherein σ is the conductivity,
A is the frequency factor, k is the Boltzmann constant, T is absolute temperature,
and Ea is the activation energy. Fig. 9 shows the temperature dependence (Arrhenius
plot) of the conductivity of each of the samples of Examples 1 to 7. Fig. 9 also shows
the temperature dependence (literature data) of the conductivity of the glass ceramic
Li
1+xTi
2Si
xP
3-xO
12·AlPO
4 (the Ohara electrolyte, X = 0.4) and that of the glass ceramic Li
1.5Al
0.5Ge
1.5(PO
4)
3 (LAGP), these glass ceramics being lithium ion-conducting oxides having particularly
high conductivity. Fig. 10 shows the X-value dependence of the activation energy Ea
of each of the samples of Examples 1 to 7, the activation energy being determined
from the Arrhenius plot. As is clear from Fig. 10, the samples in which X satisfies
the inequality 1.4 ≤ X < 2 have an activation energy less than that of Li
7La
3Zr
2O
12 (X = 2, Example 7), that is, an activation energy Ea of less than 0.34 eV. Therefore,
these samples have stable conductivity over a wide temperature range. The samples
in which X satisfies the inequality 1.5 ≤ X ≤ 1.9 have an activation energy of 0.32
eV or less. The sample in which X is 1.75 has an activation energy of 0.3 eV, which
is minimal. An activation energy of 0.3 eV is substantially equal to the lowest among
those of existent lithium ion-conducting oxides (the Ohara electrolyte has an activation
energy of 0.3 eV and LAGP has an activation energy of 0.31 eV).
5. Chemical stability
[0042] A garnet-type oxide, Li
6.75La
3Zr
1.75Nb
0.25O
12 (that is, X = 1.75, Example 5), was investigated for chemical stability at room temperature
in air. In particular, the change in conductivity of Li
6.75La
3Zr
1.75Nb
0.25O
12 with time was measured in such a manner that Li
6.75La
3Zr
1.75Nb
0.25O
12 was left in air for seven days. Fig. 11 shows the measurement results. A bulk resistance
component is constant independently of the exposure time of the garnet-type oxide
in air. This shows that the garnet-type oxide is stable at room temperature in air.
6. Potential window
[0043] The garnet-type oxide Li
6.75La
3Zr
1.75Nb
0.25O
12 (that is, X = 1.75, Example 5) was investigated for potential window. The potential
window thereof was measured in such a manner that gold was applied to a surface of
a bulk pellet of Li
6.75La
3Zr
1.75Nb
0.25O
12, a Li metal was applied to another surface thereof, and the potential of the bulk
pellet was swept at 1 mV/s within a range from 0 to 5.5 V or within a range from -
0.5 to 9.5 V (versus Li
+ ions). Fig. 12 shows the measurement results. The increase of a scanning potential
from -0.5 to 9.5 V allows a redox current to flow at above or below 0 V. This is probably
due to the oxidation or reduction of lithium. A slight oxidation current flows at
about 7 V or more. The flowing oxidation current is very small and no change in color
is visually observed. Therefore, the flowing oxidation current is not due to the decomposition
of an electrolyte but is probably due to traces of impurities contained in ceramics
or the decomposition of grain boundaries.
[Preparation of all-solid-state lithium ion secondary battery]
[0044] An all-solid-state lithium ion secondary battery 120 was prepared using the garnet-type
oxide Li
6.75La
3Zr
1.75Nb
0.25O
12 (that is, X = 1.75, Example 5) as a solid electrolyte. Fig. 13 is an illustration
of a pellet 110, made of the garnet-type oxide, including a positive electrode active
material layer 112a. Fig. 14 is a side view of the all-solid-state lithium ion secondary
battery 120. The garnet-type oxide prepared in Example 5 was formed into the pellet
110. The pellet 110 had a diameter of 13 mm and a thickness of 2 mm. The positive
electrode active material layer 112a was formed in such a manner that LiCoO
2 was deposited on a surface of the pellet 110 by a pulse laser deposition (PLD) process.
In the PLD process, a Nd-YAG laser (λ = 266 nm, E = ∼1 Jcm
-2pls
-1) was used and a chamber used to form the positive electrode active material layer
112a was maintained at an oxygen partial pressure P
O2 of 10 Pa and room temperature. The positive electrode active material layer 112a
had a diameter of 6 mm and a thickness of 500 nm. After the pellet 110 having the
positive electrode active material layer 112a was annealed at 500°C for one hour in
an electric furnace with an air atmosphere, an Au paste 112c was applied onto the
positive electrode active material layer 112a. An Au metal plate 112b serving as a
positive electrode current collector was provided on the Au paste 112c and then baked
at 400°C for 30 minutes. The positive electrode active material layer 112a, the second
regional portions 112b, and the Au paste 112c form a positive electrode 112. After
the pellet 110 having the positive electrode 112 was provided in a glove box with
an Ar atmosphere, a lithium metal serving as a negative electrode 114 was pressed
against a surface of the pellet 110 that was spaced from the positive electrode 112,
whereby the all-solid-state lithium ion secondary battery 120 was completed. The lithium
metal also serves as a reference electrode in addition to the wall deposits 114.
[Charge-discharge properties of all-solid-state lithium ion secondary battery]
[0045] The prepared all-solid-state lithium ion secondary battery 120 was subjected to charge-discharge
measurement in such a manner that the all-solid-state lithium ion secondary battery
120 was placed in an airtight container in a glove box with an Ar atmosphere and sealed
leads were taken out of the airtight container. The all-solid-state lithium ion secondary
battery 120 had an open-circuit voltage of 3.0 V. The all-solid-state lithium ion
secondary battery 120 was potentiostatically charged and discharged at a sweeping
rate of 0.2 mV/min in a scanning range from 3 to 4.3 V for one cycle. The resulting
all-solid-state lithium ion secondary battery 120 was charged and discharged at a
current of 1 mA in a sweeping potential range from 3 to 4.3 V (versus Li) for three
cycles. The resulting all-solid-state lithium ion secondary battery 120 was charged
and discharged at a current of 2 mA in a sweeping potential range from 3 to 4.3 V
(versus Li) for three cycles. The resulting all-solid-state lithium ion secondary
battery 120 was charged and discharged at a current of 1 mA in a sweeping potential
range from 3 to 4.4 V (versus Li) for three cycles. That is, the all-solid-state lithium
ion secondary battery 120 was potentiostatically charged and discharged for one cycle
and then galvanostatically charged and discharged at nine cycles. There was no rest
period between the charge-discharge cycles. Fig. 15 shows the measurement results.
Fig. 15 is a graph showing charge-discharge properties of the all-solid-state lithium
ion secondary battery 120. As is clear from Fig. 15, the all-solid-state lithium ion
secondary battery 120 demonstrated reversible charge-discharge processes. This confirms
that the all-solid-state lithium ion secondary battery 120 operates well. Fig. 16
shows the capacity of the all-solid-state lithium ion secondary battery 120 at each
cycle.
[0046] Differences between the all-solid-state lithium ion secondary battery 120 and conventional
lithium ion secondary batteries are summarized below.
(1) Comparison with nonaqueous lithium ion secondary batteries
[0047] Electrolytes for use in nonaqueous lithium ion secondary batteries have higher lithium
ion conductivity as compared with the garnet-type oxide contained in the all-solid-state
lithium ion secondary battery 120. However, the electrolytes have risks such as ignition
and deterioration due to decomposition at elevated temperatures (60°C) and therefore
cannot be used at elevated temperatures. Alternatively, some cooling units need to
be used to prevent the electrolytes from being heated to high temperatures. In contrast,
the garnet-type oxide contained therein is stable at elevated temperatures and is
inflammable. The garnet-type oxide contained therein is highly safe and has a merit
that no cooling unit is necessary. Most of conventionally reported electrolytes are
decomposed at elevated potentials (4.5 V or higher); hence, it is difficult to use
positive electrode active materials with high potential together with such electrolytes.
In contrast, the garnet-type oxide contained therein is stable at 8 V (see Fig. 12)
and therefore can be used together with substantially all of conventionally reported
positive electrode active materials.
(2) Comparison with all-solid-state lithium ion secondary batteries containing sulfide
electrolytes
[0048] There are substantially no differences in conductivity between the garnet-type oxide
contained therein and sulfide electrolytes such as Li
3.25Ge
0.25P
0.25S
4 and therefore there are substantially no differences in electrolyte resistance between
the garnet-type oxide contained therein and the sulfide electrolytes. Most of the
sulfide electrolytes reportedly have a wide potential window of about 0 to 10 V; hence,
there are no significant differences in potential window between the garnet-type oxide
contained therein and the sulfide electrolytes. The sulfide electrolytes have a problem
in chemical stability because the sulfide electrolytes react with moisture in air
to produce gaseous hydrogen sulfide. However, the garnet-type oxide contained therein
does not have such a problem.
(3) Comparison with all-solid-state lithium ion secondary batteries containing other
oxides
[0049] The garnet-type oxide contained therein has a lithium ion conductivity that is several
times greater than that of conventional garnet-type oxides. This allows the garnet-type
oxide contained therein to have an electrolyte resistance that is a fraction of that
of the conventional garnet-type oxides. Although the Ohara electrolyte (a glass ceramic),
which is conventionally known, has a lithium ion conductivity substantially equal
to that of the garnet-type oxide contained therein, the Ohara electrolyte is reduced
at about 1.5 V to cause a reduction in insulation. Therefore, it is difficult to manufacture
high-voltage batteries using the Ohara electrolyte (for example, a carbon-based negative
electrode active material that is a major material for current batteries cannot be
used). In contrast, the garnet-type oxide contained therein is not reduced even at
8 V but is stable (see Fig. 12). Therefore, the garnet-type oxide contained therein
can be used to manufacture high-voltage batteries.
Industrial Applicability
[0051] A garnet-type lithium ion-conducting oxide according to the present invention is
applicable for all-solid-state lithium ion secondary batteries. An all-solid-state
lithium ion secondary battery according to the present invention is applicable for
power supplies for industrial equipment and power supplies for home appliances.