# US 2025/0096256 A1 · Thermally stable nickel rich cathodes > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2025/0096256 A1 - Document ID: US20250096256A1 - Status: Published application - Kind: A1 - Application number: 18/502,302 - Filed: 2023-11-06 - Published: 2025-03-20 - Earliest claimed: 2023-09-18 - Assignees: GM Global Technology Operations LLC - Applicants: GM Global Technology Operations LLC - Inventors: Dewen Kong; Meiyuan Wu; Jingyuan Liu; Haijing Liu; Mark W. Verbrugge - Web page: https://patentgrep.com/patent/US20250096256A1 ## 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 - H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries - H01M 4/0404: {by coating on electrode collectors} - H01M 4/0416: {involving impregnation with a solution, dispersion, paste or dry powder (H01M4/0438 takes precedence)} - H01M 4/0435: {Rolling or calendering} - H01M 4/131: Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx - H01M 4/505: of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy - H01M 4/5825: {Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines} - H01M 4/628: {Inhibitors, e.g. gassing inhibitors, corrosion inhibitors} - H01M 2004/021: {Physical characteristics, e.g. porosity, surface area} - H01M 2004/028: {Positive electrodes} - H01M 2220/20: Batteries in motive systems, e.g. vehicle, ship, plane - Y02E 60/10: Energy storage using batteries - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract Aspects of the disclosure include systems and methods for manufacturing thermally stable nickel-rich cathodes. An exemplary method can include providing an active material including a plurality of active material particles. The plurality of active material particles include nickel. A nanoparticle slurry additive having a plurality of nanoparticles is provided. The plurality of nanoparticles include one or more of a thermally stable olivine type material, a thermally stable spinel type material, and a thermally stable manganese-nickel dioxide type material. The method includes forming a slurry by mixing the active material and the nanoparticle slurry additive. The plurality of nanoparticles form a thermal inhibitor layer on and in direct contact with a surface of the plurality of active material particles. A free-standing electrode film is formed by calendering the slurry and the free-standing electrode film is laminating to a current collector to define a thermally stable nickel-rich cathode. ## Claims ### Claim 1 A vehicle comprising: an electric motor; and a battery pack electrically coupled to the electric motor, the battery pack comprising an electrochemical cell, the electrochemical cell comprising: a cathode; an anode; and an electrolyte system between the cathode and the anode; wherein the cathode comprises: an active material comprising a plurality of active material particles, the plurality of active material particles comprising nickel; and a thermal inhibitor layer formed on and in direct contact with a surface of each active material particle of the plurality of active material particles, the thermal inhibitor layer comprising a plurality of nanoparticles, the plurality of nanoparticles comprising one or more of a thermally stable olivine type material, a thermally stable spinel type material, and a thermally stable manganese-nickel dioxide type material. ### Claim 2 (depends on 1) The vehicle of claim 1, wherein the plurality of nanoparticles comprise a combination of two or more of the thermally stable olivine type material, the thermally stable spinel type material, and the thermally stable manganese-nickel dioxide type material. ### Claim 3 (depends on 1) The vehicle of claim 1, wherein the thermally stable olivine type material comprises one or more of lithium vanadyl phosphate, lithium manganese iron phosphate, cobalt phosphate, and lithium titanium phosphate. ### Claim 4 (depends on 1) The vehicle of claim 1, wherein the thermally stable spinel type material comprises one or more of lithium manganese oxide and lithium manganese nickel oxide. ### Claim 5 (depends on 1) The vehicle of claim 1, wherein the thermally stable manganese-nickel dioxide type material comprises one or more of lithium manganese dioxide and lithium manganese nickel dioxide. ### Claim 6 (depends on 1) The vehicle of claim 1, wherein a mass ratio of the plurality of nanoparticles to the active material in the cathode comprises less than 30 percent. ### Claim 7 (depends on 1) The vehicle of claim 1, wherein a surface coverage of the active material by the plurality of nanoparticles comprises 10 to 95 percent. ### Claim 8 An electrochemical cell comprising: a cathode; an anode; and an electrolyte system between the cathode and the anode; wherein the cathode comprises: an active material comprising a plurality of active material particles, the plurality of active material particles comprising nickel; and a thermal inhibitor layer formed on and in direct contact with a surface of each active material particle of the plurality of active material particles, the thermal inhibitor layer comprising a plurality of nanoparticles, the plurality of nanoparticles comprising one or more of a thermally stable olivine type material, a thermally stable spinel type material, and a thermally stable manganese-nickel dioxide type material. ### Claim 9 (depends on 8) The electrochemical cell of claim 8, wherein the plurality of nanoparticles comprise a combination of two or more of the thermally stable olivine type material, the thermally stable spinel type material, and the thermally stable manganese-nickel dioxide type material. ### Claim 10 (depends on 8) The electrochemical cell of claim 8, wherein the thermally stable olivine type material comprises one or more of lithium vanadyl phosphate, lithium manganese iron phosphate, cobalt phosphate, and lithium titanium phosphate. ### Claim 11 (depends on 8) The electrochemical cell of claim 8, wherein the thermally stable spinel type material comprises one or more of lithium manganese oxide and lithium manganese nickel oxide. ### Claim 12 (depends on 8) The electrochemical cell of claim 8, wherein the thermally stable manganese-nickel dioxide type material comprises one or more of lithium manganese dioxide and lithium manganese nickel dioxide. ### Claim 13 (depends on 8) The electrochemical cell of claim 8, wherein a mass ratio of the plurality of nanoparticles to the active material in the cathode comprises less than 30 percent. ### Claim 14 (depends on 8) The electrochemical cell of claim 8, wherein a surface coverage of the active material by the plurality of nanoparticles comprises 10 to 95 percent. ### Claim 15 A method for manufacturing thermally stable nickel-rich cathodes, the method comprising: providing an active material comprising a plurality of active material particles, the plurality of active material particles comprising nickel; providing a nanoparticle slurry additive comprising a plurality of nanoparticles, the plurality of nanoparticles comprising one or more of a thermally stable olivine type material, a thermally stable spinel type material, and a thermally stable manganese-nickel dioxide type material; forming a slurry by mixing the active material and the nanoparticle slurry additive, wherein the plurality of nanoparticles form a thermal inhibitor layer on and in direct contact with a surface of the plurality of active material particles; forming a free-standing electrode film by calendering the slurry; and laminating the free-standing electrode film to a current collector to define a thermally stable nickel-rich cathode. ### Claim 16 (depends on 15) The method of claim 15, wherein the plurality of nanoparticles comprise a combination of two or more of the thermally stable olivine type material, the thermally stable spinel type material, and the thermally stable manganese-nickel dioxide type material. ### Claim 17 (depends on 15) The method of claim 15, wherein the thermally stable olivine type material comprises one or more of lithium vanadyl phosphate, lithium manganese iron phosphate, cobalt phosphate, and lithium titanium phosphate. ### Claim 18 (depends on 15) The method of claim 15, wherein the thermally stable spinel type material comprises one or more of lithium manganese oxide and lithium manganese nickel oxide. ### Claim 19 (depends on 15) The method of claim 15, wherein the thermally stable manganese-nickel dioxide type material comprises one or more of lithium manganese dioxide and lithium manganese nickel dioxide. ### Claim 20 (depends on 15) The method of claim 15, wherein a mass ratio of the plurality of nanoparticles to the active material in the thermally stable nickel-rich cathode comprises less than 20 percent.