# US 12,015,153 B2 · Method of producing cathode active material, and method of producing lithium ion battery > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,015,153 B2 - Document ID: US12015153B2 - Status: Granted - Kind: B2 - Application number: 17/060,956 - Filed: 2020-10-01 - Published: 2021-04-22 - Granted: 2024-06-18 - Earliest claimed: 2019-10-21 - Assignees: Toyota Jidosha Kabushiki Kaisha - Applicants: Toyota Jidosha Kabushiki Kaisha - Inventors: Issei Sugiyama - Web page: https://patentgrep.com/patent/US12015153B2 ## CPC - H01M 4/525: of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy - C01G 53/51: containing sodium - H01M 4/505: of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy - H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries - H01M 10/0562: Solid materials - H01M 10/058: Construction or manufacture - C01P 2002/52: containing elements as dopants - C01P 2002/72: by d-values or two theta-values, e.g. as X-ray diagram - C01P 2002/74: by peak-intensities or a ratio thereof only - C01P 2002/76: by a space-group or by other symmetry indications - C01P 2006/40: Electric properties - H01M 2004/028: {Positive electrodes} - Y02E 60/10: Energy storage using batteries - Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - C01G: COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F (metal hydrides {monoborane, diborane or addition complexes thereof} C01B6/00; salts of oxyacids of halogens C01B11/00; peroxides, salts or peroxyacids C01B15/00; thiosulfates, dithionites, polythionates C01B17/64; compounds containing selenium, or tellurium C01B19/00; binary compounds of nitrogen with metals C01B21/06; azides C01B21/08; {compounds containing nitrogen, other non-metals and metal C01B21/082}; metal amides C01B21/092; nitrites C01B21/50; {compounds of noble gases C01B23/0005}; phosphides C01B25/08; salts of oxyacids of phosphorus C01B25/16; carbides C01B32/90; compounds containing silicon C01B33/00; compounds containing boron C01B35/00; compounds having molecular sieve properties but not having base-exchange properties C01B37/00; compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites, C01B39/00; cyanides C01C3/08; salts of cyanamide C01C3/16; thiocyanates C01C3/20) - C01P: INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A main object is to provide a method of producing a cathode active material having a high average discharge potential, and a high degree of stability at high potential. A step of preparing a Na-doped precursor of making a transition metal oxide having a P2 structure belonging to a space group of P63/mmc; and an ion exchange step of substituting lithium for at least part of sodium contained in the transition metal oxide by an ion exchange method are included, wherein the transition metal oxide has the composition represented by NaaMnx−pNiy−qCoz−rM1p+q+rO2, where 0.5≤a≤1, x+y+z=1, 3≤4x+2y+3z≤3.5, and 0.05≤p+q+r<0.25, M1 is Al or Mo, when M1 is Al, p is not equal to q, and any one of p and q is not 0. ## Claims ### Claim 1 A method of producing a lithium ion battery, the method comprising: a step of making a cathode active material layer containing a cathode active material; and a step of using the cathode active material layer, an anode active material layer containing an anode active material, and an electrolyte layer containing an electrolyte, to arrange the electrolyte layer between the cathode active material layer and the anode active material layer, wherein the cathode active material is produced by a method comprising: a step of preparing a Na-doped precursor of making a transition metal oxide having a P2 structure belonging to a space group of P63/mmc; and an ion exchange step of substituting lithium for at least part of sodium contained in the transition metal oxide by an ion exchange method, wherein the transition metal oxide has the composition represented by NaaMnx-pNiy-qCoz-rM1p+q+rO2, where 0.5≤a≤1, x+y+z=1, 3≤4x+2y+3z≤3.5, and 0.05≤p+q+r<0.25, M1 is Al or Mo, when M1 is Al, p is not equal to q, and any one of p and q is not 0, and a O2 structure and a O3 structure coexist in a single particle of the cathode active material obtained by the ion exchange step, and wherein an initial average discharge potential of the cathode active material is at least 3.76V. ### Claim 2 (depends on 1) The method according to claim 1, wherein the electrolyte layer is a solid electrolyte layer containing a solid electrolyte. ### Claim 3 (depends on 1) The method according to claim 1, wherein a proportion of the O2 structure and the O3 structure in the cathode active material is such that an abundance of O2 structure/O3 structure is 0.1 to 3.0. ### Claim 4 (depends on 1) The method according to claim 1, wherein Co is cobalt (III). ### Claim 5 A lithium ion battery comprising: a cathode active material layer containing a cathode active material; an anode active material layer containing an anode active material; and an electrolyte layer containing an electrolyte, the electrolyte layer arranged between the cathode active material layer and the anode active material layer, wherein the cathode active material has the composition represented by LibNacMnl−sNim−tCon−uM2s+t+uO2 where 0