Manufacturing thick electrodes for Li-ion batteries is a challenging task to fulfill, but leads to higher energy densities inside the cell. Water-based processing even adds an extra level of complexity to the procedure. The focus of this work is to implement a multi-layered coating in an industrially relevant process, to overcome issues in electrode integrity and to enable high electrochemical performance. LiNi0.8Mn0.1Co0.1O2 (NMC811) was used as the active material to fabricate single- and multi-layered cathodes with areal capacities of 8.6 mA h cm−2. A detailed description of the manufacturing process is given to establish thick defect-free aqueous electrodes. Good inter-layer cohesion and adhesion to the current collector foil are achieved by multi-layering, as confirmed by optical analysis and peel testing. Furthermore, full cells were assembled and rate capability tests were performed. These tests show that by multi-layering, an increase in specific discharge capacity (e.g., 20.7% increase for C/10) can be established for all tested C-rates.

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The spray roasting process is recently applied for production of catalysts and single metal oxides. In our study, it was adapted for large-scale manufacturing of a more complex mixed oxide system, in particular symmetric lithium nickel manganese cobalt oxide (LiNi 1/3 Co 1/3 Mn 1/3 O 2 -NMC), which is already used as cathode material in lithium-ion batteries. An additional lithiation step was coupled with the main process in order to obtain the desired layered structure. Thermogravimetric analysis and high-temperature X-ray diffractometry built the basis for determining suitable synthesis temperature regions for the used chloride precursors and the post-treatment step. The optimized process was proven on an industrial pilot line where a setup for minimum production capacity of 12 kg h −1 was possible. The powder obtained directly after roasting had a very striking morphology compared to the final lithiated product. Hollow aggregates (≥250 μm) with overall 10.926 m 2 g −1 surface area and a pore diameter of 3.396 nm were observed. Their well-faceted primary particles were converted into nanosized spheres after lithiation, building a few micrometer big high-porous agglomerates. Actual composition was verified by inductively coupled plasma atomic emission spectroscopy analysis, and the crystal structure and corresponding unit cell parameters were identified and confirmed by Rietveld fit of the derived X-ray diffraction pattern. The initial electrochemical measurements show a 149-mAh g −1 discharge capacity, as determined from cyclic voltammetry.

The chemical diffusion coefficient in LiNi 1/3 Mn 1/3 Co 1/3 O 2 was determined via the galvanostatic intermittent titration technique in the voltage range 3 to 4.2 V. Calculated diffusion coefficients in these layered oxide cathodes during charging and discharging reach a minimum at the open-circuit voltage of 3.8 V and 3.7 V vs. Li/Li + , respectively. The observed minima of the chemical diffusion coefficients indicate a phase transition in this voltage range. The unit cell parameters of LiNi 1/3 Mn 1/3 Co 1/3 O 2 cathodes were determined at different lithiation states using ex situ crystallographic analysis. It was shown that the unit cell parameter variation correlates well with the observed values for chemical diffusion in NMC cathodes; with a notable change in absolute values in the same voltage range. We relate the observed variation in unit cell parameters to the nickel conversion into the trivalent state, which is Jahn-Teller active, and to the rearrangement of lithium ions and vacancies.