Ni-rich LiNixMnyCo1-x-yO2 (x > 0.5) (NMC) materials have attracted a great deal of interest as promising cathode candidates for Li-ion batteries due to their low cost and high energy density. However, several issues, including sensitivity to moisture, difficulty in reproducibly preparing well-controlled morphology particles and, poor cyclability, have hindered their large scale deployment; especially for electric vehicle (EV) applications. In this work, we have developed a uniform, highly stable, high-energy density, Ni-rich LiNi0.6Mn0.2Co0.2O2 cathode material by systematically optimizing synthesis parameters, including pH, stirring rate, and calcination temperature. The particles exhibit a spherical morphology and uniform size distribution, with a well-defined structure and homogeneous transition-metal distribution, owing to the well-controlled synthesis parameters. The material exhibited superior electrochemical properties, when compared to a commercial sample, with an initial discharge capacity of 205 mAh/g at 0.1 C. It also exhibited a remarkable rate capability with discharge capacities of 157 mAh/g and 137 mAh/g at 10 and 20 C, respectively, as well as high tolerance to air and moisture. In order to demonstrate incorporation into a commercial scale EV, a large-scale 4.7 Ah LiNi0.6Mn0.2Co0.2O2 Al-full pouch cell with a high cathode loading of 21.6 mg/cm2, paired with a graphite anode, was fabricated. It exhibited exceptional cyclability with a capacity retention of 96% after 500 cycles at room temperature. This material, which was obtained by a fully optimized scalable synthesis, delivered combined performance metrics that are among the best for NMC materials reported to date.
Keywords: high loading electrode; high stability; high-energy cathode; layered oxide cathode; lithium-ion batteries.