High performance lfp cell with active material composite for high rate applications

A cathode (102) of a lithium-ion cell (100), the cathode (102) comprising:

• a porous current collector coated with a cathode slurry,
• wherein the cathode slurry is formed by mixing an active material composite with one or more of:
• 3-8% of binders, 2 to 4% of conductive diluents, and 40-55% of a solvent,
• wherein the_active material composite comprises a cathode active material and a carbon-based conductive material, wherein the cathode active material is in a ratio of 80-95% by weight and the carbon-based conductive material is in a ratio of 5-20% by weight,
• wherein the cathode active material is combined with the carbon-based conductive material using a ball milling process in a vacuum-controlled environment maintained at room temperature to form the active material composite, and
• wherein during the ball milling process, the cathode active material and the carbon based conductive material are mixed in the ball mill and subjected to rotation at a speed of 1500 to 2500 rpm to obtain a carbon coating on the cathode active material and resulting in a particle size D50 in a range from 2 to 6 micrometers.

A lithium-ion cell (100) comprising:

• a cathode (102) comprising:
• a porous current collector coated with a cathode slurry,
• wherein the cathode slurry is formed by mixing an active material composite with one or more of:
• 3-8% of binders, 2-4% of conductive diluents, and 40-55% of a solvent,
• wherein the active material composite comprises lithium iron phosphate (LFP) active material and carbon-based conductive materials, wherein the LFP active material is in a ratio of 80-95% by weight and the carbon-based conductive materials is in a ratio of 5-20% by weight,
• and
• wherein the cathode-LFP active material is combined with the carbon-based conductive materials using a ball milling process in a vacuum-controlled environment maintained at room temperature to form the active material composite, and
• wherein during the ball milling process, the LFP active material and the carbon based conductive materials are mixed in the ball mill and subjected to rotation at a speed of 1500 to 2500 rpm to obtain a carbon coating on the LFP active material and resulting in a particle size D50 in a range from 2 to 6 micrometers;
• and
• an anode (104) comprising:
• a conductive foil substrate coated with an anode slurry,
• wherein the anode slurry is formed by mixing an anode active material with one or more of:
• conductive diluents, binders and a solvent,
• wherein the anode active material comprising comprise 80-95% by weight of graphite, and one or more of 5-20% by weight of silicon, and 5-20% by weight of hard carbon,
• wherein the one or more conductive diluents are in a range of 2 to 4% and the binders are in a range of 4 to 8% by weight, and
• wherein the solvent is in a range of 40-55% by weight;
• a separator (108) positioned between the cathode and the anode to facilitate ion transport;
• and
• an electrolyte (106) in contact with the cathode and the anode, wherein the electrolyte comprises a lithium salt combined with additives to facilitate lithium-ion transport within the cell.