Battery Cathode Heating to Reduce Gassing
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Solution Overview
Problem
Conventional battery manufacturing processes often result in high rates of gassing, leading to potential leaks and requiring pre-discharge steps, which complicates the manufacturing process and reduces cell capacity.
Innovation Solution
A method for making batteries involves heating cathodes in an oxygen-rich atmosphere or vacuum to reduce water content and eliminate Mn3O4, using specific cathode materials and binders, and assembling them with anodes and separators in a controlled environment to minimize gassing and enhance capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery manufacturing processes are used, then the manufacturing process is simple, but high rates of gassing occur leading to potential leaks and requiring pre-discharge steps
Solution Approach 1:
The cathode is pre-heated in an oxygen-rich atmosphere or vacuum before battery assembly to reduce water content and eliminate Mn3O4. This preliminary treatment prevents gassing issues during battery operation, eliminating the need for post-assembly pre-discharge steps and reducing manufacturing complexity.
Solution Approach 2:
The invention changes the water content parameter of the cathode material to about 600 ppm or less and reduces Mn3O4 to about 0.1 percent by weight or less through controlled heating. These parameter changes in the cathode material properties directly reduce gassing rates and improve battery reliability.
2Productivity
If conventional cathode materials are used, then manufacturing is easier, but pre-discharge steps are required which reduces cell capacity
Solution Approach 1:
The cathode undergoes preliminary heating treatment in an oxygen-rich atmosphere or vacuum to achieve the desired water content and Mn3O4 levels before assembly. This advance preparation eliminates the need for capacity-reducing pre-discharge steps, thereby increasing productive cell capacity while maintaining ease of manufacture.
Solution Approach 2:
By controlling the heating parameters (temperature, time, atmosphere) to achieve specific cathode material properties (water content ≤600 ppm, Mn3O4 ≤0.1%), the invention enables direct assembly without pre-discharge, thus maximizing cell capacity while keeping manufacturing simple.
3Reliability
If cathodes with higher water content are used, then manufacturing is simpler, but gassing rates increase and leaks occur
Solution Approach 1:
The invention specifies precise parameter changes in the cathode material: heating to reduce water content to about 600 ppm or less and Mn3O4 to about 0.1 percent by weight or less. These controlled parameter changes improve leak resistance by reducing gassing while maintaining ease of manufacture through a straightforward heating process.
Solution Approach 2:
Heating the cathode in an oxygen-rich atmosphere accelerates the oxidation and removal of volatile components including water and Mn3O4. This accelerated oxidation process efficiently achieves the desired low water content and Mn3O4 levels, improving leak resistance without complicating manufacturing.
4Productivity
If pre-discharge steps are implemented, then gassing is controlled, but manufacturing complexity increases and cell capacity decreases
Solution Approach 1:
The cathode is pre-treated by heating in an oxygen-rich atmosphere or vacuum to eliminate water and Mn3O4 before assembly. This preliminary action controls gassing inherently, eliminating the need for post-assembly pre-discharge steps, thereby improving manufacturing efficiency and preserving cell capacity.
Solution Approach 2:
By changing the cathode material parameters (water content ≤600 ppm, Mn3O4 ≤0.1%) through controlled heating, the invention achieves inherent gassing control without requiring additional pre-discharge steps, thus improving productivity while maintaining reliability.
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
The approach results in batteries with reduced gassing rates, increased cell capacity, and simplified manufacturing by eliminating the need for pre-discharge steps, while also making the batteries less prone to leaks.
Implementation Method 1
heating at least one cathode including a cathode material in an atmosphere that includes oxygen... heating the cathode in a vacuum... heating a cathode in a vacuum can include heating the cathode until the cathode material includes about 600 ppm of water or less
Implementation Method 2
heating at least one cathode including a cathode material in an atmosphere that includes oxygen... heating the cathode until the cathode material has a differential scanning calorimetry peak at from about 240° C. to about 310° C.
Data Source
AI summary
Batteries and related compositions and methods are disclosed. In some embodiments, a method of making a battery can include heating at least one cathode including a cathode material in an atmosphere including oxygen, heating the cathode in a vacuum, adding the cathode into a housing, adding a separator into the housing, and adding an anode into the housing.