Cathode material and method of manufacturing

Abstract

A cathode material for a lithium primary battery can include a low surface area lithiated manganese dioxide, a mixture of lithiated manganese dioxide and CF x , or both. The cathode materials can provide high capacity and voltage with low gassing.

1 . A cathode material comprising an irreversible high capacity material and a reversible low capacity material.  
     
     
         2 . The cathode material of  claim 1 , wherein the reversible low capacity material includes a lithiated manganese dioxide.  
     
     
         3 . The cathode material of  claim 1 , wherein the irreversible high capacity material includes a carbon fluoride.  
     
     
         4 . The cathode material of  claim 2 , wherein the irreversible high capacity material includes a carbon fluoride.  
     
     
         5 . The cathode material of  claim 4 , wherein the lithiated manganese dioxide and the carbon fluoride are blended.  
     
     
         6 . The cathode material of  claim 4 , wherein the lithiated manganese dioxide includes an electrolytic manganese dioxide or a chemical manganese dioxide.  
     
     
         7 . The cathode material of  claim 4 , wherein the carbon fluoride is CF x .  
     
     
         8 . The cathode material of  claim 4 , wherein the lithiated manganese dioxide and the carbon fluoride are present in a ratio in the range of 1:99 to 99:1 by weight.  
     
     
         9 . The cathode material of  claim 4 , wherein the lithiated manganese dioxide and the carbon fluoride are present in a ratio in the range of 5:95 to 95:5 by weight.  
     
     
         10 . The cathode material of  claim 4 , wherein the lithiated manganese dioxide and the carbon fluoride are present in a ratio in the range of 25:75 to 75:25 by weight.  
     
     
         11 . The cathode material of  claim 4 , wherein the lithiated manganese dioxide and the carbon fluoride are present in a ratio in the range of 20:80 to 80:20 by weight.  
     
     
         12 . The cathode material of  claim 2 , wherein the lithiated manganese dioxide includes a low surface area lithiated manganese dioxide.  
     
     
         13 . The cathode material of  claim 11 , wherein the low surface area lithiated manganese dioxide has a specific surface area of between 0.50 and 20.0 m 2/g.  
     
     
         14 . The cathode material of  claim 11 , wherein the low surface area lithiated manganese dioxide has a specific surface area of between 10.0 and 15.0 m 2 /g.  
     
     
         15 . A cathode material comprising a low surface area lithiated manganese dioxide.  
     
     
         16 . The cathode material of  claim 14 , wherein the low surface area lithiated manganese dioxide has a specific surface area of between 0.50 and 20.0 m 2 /g.  
     
     
         17 . The cathode material of  claim 14 , wherein the low surface area lithiated manganese dioxide has a specific surface area of between 10.0 and 15.0 m 2 /g.  
     
     
         18 . The cathode material of  claim 14 , wherein the low surface area lithiated manganese dioxide, when mixed with an electrolyte including an organic solvent and a lithium salt, produces a gas pressure of no more than 16 PSI after 100 hours at 70° C.  
     
     
         19 . A primary lithium battery comprising: 
 a cathode including an irreversible high capacity material and a reversible low capacity material;    an anode including lithium; and    a separator between the cathode and the anode.    
     
     
         20 . The battery of  claim 18 , wherein the reversible low capacity material includes a lithiated manganese dioxide.  
     
     
         21 . The battery of  claim 19 , wherein the lithiated manganese dioxide includes an electrolytic manganese dioxide or a chemical manganese dioxide.  
     
     
         22 . The battery of  claim 19 , wherein the battery delivers a capacity at least 40% greater than the sum of the expected capacities of the lithiated manganese dioxide and the irreversible high capacity material under high drain conditions.  
     
     
         23 . The battery of  claim 18 , wherein the irreversible high capacity material includes a carbon fluoride.  
     
     
         24 . The battery of  claim 19 , wherein the irreversible high capacity material includes a carbon fluoride.  
     
     
         25 . The battery of  claim 23 , wherein the lithiated manganese dioxide and the carbon fluoride are blended.  
     
     
         26 . The battery of  claim 23 , wherein the carbon fluoride is CF x .  
     
     
         27 . The battery of  claim 23 , wherein the lithiated manganese dioxide and the carbon fluoride are present in a ratio in the range of 1:99 to 99:1 by weight.  
     
     
         28 . The battery of  claim 23 , wherein the lithiated manganese dioxide and the carbon fluoride are present in a ratio in the range of 5:95 to 95:5 by weight.  
     
     
         29 . The battery of  claim 23 , wherein the lithiated manganese dioxide and the carbon fluoride are present in a ratio in the range of 25:75 to 75:25 by weight.  
     
     
         30 . The battery of  claim 23 , wherein the lithiated manganese dioxide and the carbon fluoride are present in a ratio in the range of 20:80 to 80:20 by weight.  
     
     
         31 . The battery of  claim 23 , further comprising an electrolyte including an organic solvent.  
     
     
         32 . The battery of  claim 23 , wherein the lithiated manganese dioxide includes a low surface area lithiated manganese dioxide.  
     
     
         33 . The battery of  claim 30 , wherein the low surface area lithiated manganese dioxide has a specific surface area between 0.50 and 20.0 m 2 /g.  
     
     
         34 . The battery of  claim 30 , wherein the low surface area lithiated manganese dioxide has a specific surface area between 10.0 and 15.0 m 2 /g.  
     
     
         35 . The battery of  claim 30 , wherein the low surface area lithiated manganese dioxide, when mixed with an electrolyte including an organic solvent and a lithium salt, produces a gas pressure of no more than 16 PSI after 100 hours at 70° C.  
     
     
         36 . The battery of  claim 30 , wherein the lithiated manganese dioxide and the carbon fluoride are present in a ratio in the range of 1:99 to 99:1 by weight.  
     
     
         37 . The battery of  claim 30 , wherein the lithiated manganese dioxide and the carbon fluoride are present in a ratio in the range of 5:95 to 95:5 by weight.  
     
     
         38 . The battery of  claim 30 , wherein the lithiated manganese dioxide and the carbon fluoride are present in a ratio in the range of 25:75 to 75:25 by weight.  
     
     
         39 . The battery of  claim 30 , wherein the lithiated manganese dioxide and the carbon fluoride are present in a ratio in the range of 20:80 to 80:20 by weight.  
     
     
         40 . The battery of  claim 30 , further comprising an electrolyte including an organic solvent.  
     
     
         41 . A primary lithium battery comprising: 
 a cathode including a low surface area lithiated manganese dioxide;    an anode including lithium; and    a separator between the cathode and the anode.    
     
     
         42 . The battery of  claim 38 , wherein the low surface area lithiated manganese dioxide has a specific surface area between 0.50 and 20.0 m 2 /g.  
     
     
         43 . The battery of  claim 38 , wherein the low surface area lithiated manganese dioxide has a specific surface area between 10.0 and 15.0 m 2 /g.  
     
     
         44 . The battery of  claim 38 , further comprising an electrolyte including an organic solvent.  
     
     
         45 . The battery of  claim 38 , wherein the low surface area lithiated manganese dioxide, when mixed with an electrolyte including an organic solvent and a lithium salt, produces a gas pressure of no more than 16 PSI after 100 hours at 70° C.  
     
     
         46 . A method of manufacturing a cathode active material comprising combining an irreversible high capacity material and a reversible low capacity material.  
     
     
         47 . The method of  claim 43 , wherein the reversible low capacity material includes a lithiated manganese dioxide.  
     
     
         48 . The method of  claim 43 , wherein the irreversible high capacity material includes a carbon fluoride.  
     
     
         49 . The method of  claim 44 , wherein the irreversible high capacity material includes a carbon fluoride.  
     
     
         50 . A method of manufacturing a primary battery comprising combining a lithiated manganese dioxide and a carbon fluoride to form a cathode material.  
     
     
         51 . The method of  claim 47 , wherein the carbon fluoride is CF x .  
     
     
         52 . The method of  claim 47 , further comprising forming a cathode including the cathode material.  
     
     
         53 . The method of  claim 49 , further comprising assembling the cathode with an anode including lithium in a housing.  
     
     
         54 . The method of  claim 50 , further comprising assembling the cathode with an electrolyte including an organic solvent in the housing.  
     
     
         55 . The method of  claim 47 , wherein the lithiated manganese dioxide includes a low surface area lithiated manganese dioxide.  
     
     
         56 . The method of  claim 52 , wherein the low surface area lithiated manganese dioxide has a specific surface area between 0.50 and 20.0 m 2 /g.  
     
     
         57 . The method of  claim 52 , wherein the low surface area lithiated manganese dioxide has a specific surface area between 10.0 and 15.0 m 2 /g.  
     
     
         58 . A method of manufacturing a primary battery comprising forming a cathode material including a low surface area lithiated manganese dioxide.  
     
     
         59 . The method of  claim 55 , wherein the low surface area lithiated manganese dioxide has a specific surface area between 0.50 and 20.0 m 2 /g.  
     
     
         60 . The method of  claim 55 , wherein the low surface area lithiated manganese dioxide has a specific surface area between 10.0 and 15.0 m 2 /g.