Fabrication of high tap density LiFe0.6Mn0.4PO4/C microspheres by a double carbon coating–spray drying method for high rate lithium ion batteries

Spherical LiFe0.6Mn0.4PO4/C particles with high tap density were successfully synthesized by sintering spherical precursor powders prepared by a modified spray drying method with a double carbon coating process. The obtained secondary spheres were made of carbon-coated nanocrystallines (∼100 nm), exhibiting a high tap density of 1.4 g cm−3. The LiFe0.6Mn0.4PO4/C microspheres had a reversible capacity of 160.2 mAh g−1 at 0.1C, and a volume energy density of 801.5 Wh L−1 which is nearly 1.4 times that of their nano-sized counterparts. This spherical material showed remarkable rate capability by maintaining 106.3 mAh g−1 at 20C, as well as excellent cycleablity with 98.9% capacity retention after 100 cycles at 2C and 200 cycles at 5C. The excellent electrochemical performance and processability of the LiFe0.6Mn0.4PO4/C microspheres make them very attractive as cathode materials for use in high rate battery application.