Battery Cell Cathode Module Recovery for Low-Impact Remanufacturing
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Solution Overview
Problem
Current Lithium ion battery recycling techniques are complex, energy-intensive, and environmentally impactful, requiring hazardous chemicals and significant raw material extraction, which increases the cost of ownership and environmental footprint of battery packs.
Innovation Solution
A method of recovering a cathode module from a used battery cell and assembling a new battery cell using the recovered module, along with a new anode module, electrolyte, and separator, reducing processing steps, energy consumption, and hazardous chemical use, while re-lithiating the cathode module to restore capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If known recycling techniques (mechanical, hydrometallurgical, pyrometallurgical processes) are used to extract materials from used battery cells, then reusable materials can be recovered, but the process becomes complex, energy-intensive, and requires significant quantities of hazardous chemicals
Solution Approach 1:
The invention extracts and recovers the cathode module directly from the used battery cell as a complete functional unit, rather than breaking it down into individual materials. This selective extraction of the valuable cathode component avoids the complex multi-step processes needed to recover individual metals and chemicals, while still achieving material recovery for reuse in new battery cells
Solution Approach 2:
The invention recovers the cathode module for reuse in new battery cells while discarding only the anode module and other non-valuable components. This selective recovery approach maintains process simplicity by focusing on recovering the most valuable component (cathode) without requiring complex processes to recover all materials
2Loss of substance
If known recycling techniques (mechanical, hydrometallurgical, pyrometallurgical processes) are used to extract materials from used battery cells, then reusable materials can be recovered, but the process consumes significant energy and requires hazardous chemicals
Solution Approach 1:
The invention extracts the cathode module as a complete unit from the used battery cell, avoiding the energy-intensive processes of crushing, shredding, and chemical leaching required by conventional methods. This direct extraction approach recovers reusable materials with significantly reduced energy consumption by eliminating multiple high-energy processing steps
3Loss of substance
If known recycling techniques are used to extract materials from used battery cells, then reusable materials can be recovered, but the process has significant environmental impact and increases cost of ownership
Solution Approach 1:
The invention extracts the cathode module directly from used battery cells without using hazardous chemicals or extreme conditions. This clean extraction method recovers reusable materials with minimal environmental impact, avoiding the pollution and waste associated with conventional hydrometallurgical and pyrometallurgical processes
Solution Approach 2:
The invention recovers the cathode module for reuse while discarding only the anode and other non-valuable components. This selective recovery approach reduces environmental impact by minimizing waste generation and eliminating the need for hazardous chemical treatments required to process all battery materials
Data Source
AI summary
A method of manufacturing a battery cell is disclosed. The method comprises recovering a cathode module from a used battery cell, assembling a new battery cell using the recovered cathode module. The used battery cell may be from a battery pack which has failed or reached end-of-life. The new battery cell may comprise a new anode module, a new electrolyte and/or a new separator. This may allow a battery cell to be manufactured in a manner which is more cost effective and environmentally sustainable than prior techniques.