Carbon Material Dispersion Metallic Impurity Removal
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Solution Overview
Problem
Existing methods for removing metallic components from carbon materials, such as carbon black and graphite, are inefficient and require complex processes, leading to impurities in applications like lithium-ion batteries, which can cause internal short circuits and reduced battery performance.
Innovation Solution
A two-step magnetic separation process where carbon materials are first treated on a rotating magnetic roll in a dry state to remove metallic components, followed by a second separation in a wet state, using a magnet in the dispersion medium to further purify the carbon material dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods (chelating agents, cation exchange resin) are used to remove metallic components, then metallic components can be removed, but the process becomes complex and requires additional separation steps
Solution Approach 1:
The patent extracts and removes metallic components directly from the carbon material dispersion using magnetic separation. The magnetic roll selectively attracts and removes metallic particles from the dispersion, separating them from the carbon material without requiring complex chemical processes or additional separation steps.
Solution Approach 2:
The patent replaces chemical methods (chelating agents, cation exchange resin) with a magnetic field-based mechanical system. The magnetic roll uses magnetic attraction force to remove metallic components, eliminating the need for chemical reactions and subsequent filtration or separation operations.
2Reliability
If magnetic separation is used to remove metallic components, then metallic components can be removed, but metallic components may remain in the dispersion if not properly separated
Solution Approach 1:
The patent performs preliminary magnetic separation of metallic components from the carbon material before the carbon material is used in battery production. The magnetic roll is positioned to intercept and remove metallic particles early in the process, preventing them from contaminating the final product and ensuring high purity carbon material dispersion.
Solution Approach 2:
The magnetic roll acts as an intermediary device between the carbon material dispersion and the final product. It selectively interacts with metallic components through magnetic attraction, capturing them on its surface while allowing the carbon material to pass through, thus mediating the separation process.
3Productivity
If metallic components are present in carbon material, then carbon material can be produced, but battery performance deteriorates due to internal short circuits and self-discharge
Solution Approach 1:
The patent extracts and removes metallic components from the carbon material production process using magnetic separation. By capturing metallic particles on the magnetic roll before they can enter the battery, the system maintains carbon material production efficiency while preventing battery performance deterioration from internal short circuits and self-discharge.
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 method effectively removes metallic components, resulting in high-quality carbon material dispersions with low metallic content, improving the stability and cycle characteristics of lithium-ion batteries by preventing internal short circuits and self-discharge.
Implementation Method 1
a first magnetic separation step in which, in a dry state in which the carbon material is in a powdered and/or granulated form, the powdered and/or granulated form of the carbon material is applied on a surface of a rotating magnetic roll to remove a metallic component from the carbon material
Implementation Method 2
a second magnetic separation step in which a magnet element is placed in a carbon material dispersion in order to remove the metallic component from the carbon material dispersion
Data Source
AI summary
The disclosed is a method for producing a carbon material dispersion which removes efficiently and reliably metallic components from carbon materials, and that provides a carbon material dispersion of a high product quality and stable electrical properties. The method comprises a first magnetic separation step in which the powdered and/or granulated carbon material C is applied to the surface of a rotating magnetic roll 130 to remove the metallic component M from the carbon material in the dry state of the powdered and granulated carbon material C; and a second magnetic separation step in which a magnet element 310 is placed in a carbon material dispersion D, in which the carbon material from which the metallic component has been removed in the first magnetic separation step is dispersed in a dispersing medium, in advance of the second magnetic separation step.