Battery Cell Assembly Recycling With Intact-Cell Size Reduction
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Solution Overview
Problem
The increasing volume of batteries, particularly lithium ion batteries, poses challenges for environmentally friendly disposal and recycling, as existing methods struggle to efficiently process and recover materials from spent battery cell assemblies.
Innovation Solution
A method and system for recycling battery cell assemblies involve reducing them into smaller pieces while keeping the battery cells intact to retain electrolyte, followed by burning off the electrolyte in a furnace, shredding the remaining pieces, and sorting them by material type into different groups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cell assemblies are reduced into smaller pieces while keeping battery cells intact to retain electrolyte, then safety is improved by preventing electrolyte leakage, but device complexity increases due to the need for controlled breaking mechanisms
Solution Approach 1:
The battery cell assembly is segmented into smaller pieces while maintaining the integrity of individual battery cells. The breaking mechanism divides the assembly into manageable sections that can be processed separately, preventing electrolyte leakage while enabling controlled size reduction for subsequent processing steps.
Solution Approach 2:
An intermediary breaking mechanism is introduced between the battery cell assembly and the furnace/shredding processes. This intermediary device controls the breaking process to maintain cell integrity, serving as a buffer that protects against direct damage from high-temperature or high-force processing.
2Productivity
If battery cell assemblies are broken apart to reduce size for processing, then productivity is improved by enabling easier handling and processing, but the risk of electrolyte leakage increases compromising safety
Solution Approach 1:
The breaking process is performed as a preliminary step before furnace processing, but is carefully controlled to maintain cell integrity. The assembly is broken into smaller pieces that are still manageable in size, preparing them for subsequent processing while preventing premature electrolyte exposure.
Solution Approach 2:
The breaking mechanism uses controlled force parameters that are sufficient to reduce assembly size but insufficient to breach battery cell casings. By carefully adjusting the breaking force and distribution, the system achieves size reduction without compromising cell integrity or causing electrolyte leakage.
3Device complexity
If the entire battery cell assembly is processed as one unit, then device complexity is reduced, but manufacturing precision is worsened due to difficulty in separating different materials
Solution Approach 1:
The battery cell assembly is segmented into smaller pieces that maintain cell integrity, creating intermediate units that are easier to handle and process. This segmentation facilitates subsequent material separation by reducing the overall size and complexity of the assembly while preserving the structural integrity of individual cells for proper material recovery.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the safe and efficient recycling of battery materials, preventing electrolyte leakage and allowing for the recovery of valuable metals and plastics, thus promoting sustainable battery disposal and resource recovery.
Implementation Method 1
directing the smaller pieces to a furnace for burning off electrolyte in the battery cells
Data Source
AI summary
Systems, apparatus, and methods for recycling battery cells and/or battery cell assemblies for metallurgical recovery. In some embodiments, the battery cells and/or battery cell assemblies can be discharged/deactivated, reduced to smaller pieces, thermally decomposed, and then sorted into different component materials.