Cracking the Lithium Puzzle: South Korean Scientists Solve Residual Li Problem in High-Nickel EV Batteries

Ulsan Advanced Energy Technology R&D Center

In a landmark breakthrough for the electric vehicle (EV) battery industry, researchers at the Ulsan Advanced Energy Technology R&D Center, part of the Korea Institute of Energy Research (KIER), have addressed a long-standing issue undermining the stability and performance of high-nickel (high-Ni) cathode materials. Their findings could significantly accelerate the development of next-generation lithium-ion batteries with higher energy density and longer lifespan.

This critical advancement, published on Newswise, reveals that residual lithium (Li) compounds—long blamed for battery degradation—are not just a surface-level problem. Instead, they lurk deep within the internal particle structures of cathodes, disrupting electrode uniformity and leading to performance issues.

Why High-Nickel Cathodes Matter

High-Ni cathode materials, with nickel content as high as 80%, are at the forefront of EV battery innovation. Their high energy density allows for longer driving ranges without increasing battery size. However, they also present a major challenge: as nickel content rises, so does the amount of residual Li—leftover lithium compounds that destabilize the electrode slurry and reduce adhesion between particles.

This “gelation” effect causes the electrode slurry to harden unevenly, degrading manufacturing stability and leading to premature aging and reduced battery performance.

The Game-Changing Discovery

Until now, residual Li was thought to primarily exist on the surface of cathode particles. Industry-standard techniques—like water rinsing and surface coatings—have been largely ineffective in addressing this. But the team led by Dr. Wooyoung Jin and Dr. Hyungyeon Cha made a key discovery: residual Li also crystallizes between internal grains of cathode particles.

This new understanding was made possible by cutting-edge tools including high-resolution electron microscopy, nitrogen adsorption analysis, and electron energy loss spectroscopy. The researchers confirmed that residual lithium forms crystalline structures in the intergranular pores between particles—something conventional cleaning processes simply can't reach.

Enter the Single-Crystal Solution

Based on these findings, the team proposed a new material design strategy using single-crystal structured high-Ni cathodes. Unlike traditional polycrystalline cathodes, single-crystal materials have no grain boundaries—eliminating the porous regions where residual Li tends to accumulate.

The result? A reduction of up to 54% in residual lithium compared to conventional cathode designs. This brings the industry significantly closer to its goal of maintaining residual Li below 2,000 ppm—an important milestone for commercial viability and battery safety.

Implications for EV Batteries and Beyond

This discovery could reshape the lithium-ion battery landscape, particularly as EV manufacturers race to deliver longer-lasting and safer vehicles. Improved cathode material integrity will enhance not only energy density but also manufacturing consistency, thermal stability, and overall battery life.

Furthermore, the proposed design strategy aligns with scalable manufacturing practices, ensuring compatibility with industrial processes—a critical factor for rapid adoption in global supply chains.

A Turning Point for Battery Science

“This study marks the first in-depth analysis to move beyond surface-level approaches and examine residual Li issues within the internal structure of cathode particles,” said Dr. Jin. “It represents a critical turning point in understanding the structural stability and performance degradation mechanisms of high-Ni cathodes.”

The work, supported by South Korea’s Ministry of Science and ICT, was featured as the cover article in the February edition of the Journal of Materials Chemistry A—a top-tier journal in the materials science community (Impact Factor: 10.7).

Read the Full Article

Breakthrough in Next-Generation EV Battery: Residual Li Issue in High-Ni Cathode Materials Resolved

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high-nickel cathode lithium-ion batteries, residual lithium in EV batteries, battery performance degradation, single-crystal cathode design, gelation in battery slurry, EV battery lifespan enhancement, lithium-ion battery innovation, Korea Institute of Energy Research KIER, Ulsan battery research center, Journal of Materials Chemistry A battery research

#EVBatteries #HighNickelCathodes #BatteryInnovation #LithiumIonTech #CleanEnergy #MaterialsScience #BatteryPerformance #KoreanResearch #EnergyStorage #QuantumServerNetworks

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