Cathode Precursor Particles With Uniform Alkali Distribution
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Solution Overview
Problem
The high cost of cathode active materials in secondary batteries, which account for 30 to 50% of the material costs, limits the reduction of battery production costs using conventional technologies, necessitating a novel approach to enhance productivity and performance.
Innovation Solution
Development of novel precursor particles with alkali metal and/or alkaline earth metal uniformly distributed within transition metal precursor particles, eliminating the need for a mixing process and significantly shortening reaction time through enhanced diffusion rates and high packing density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional precursor preparation methods are used, then production cost is reduced through material composition changes, but productivity improvement and production cost reduction are limited
Solution Approach 1:
The patent combines multiple precursor materials (transition metal precursor, alkali metal precursor, and alkaline earth metal precursor) into a single integrated precursor particle structure. This merging eliminates the need for separate mixing processes and enables direct sintering, thereby improving productivity without significantly increasing process complexity.
Solution Approach 2:
The patent performs preliminary preparation of a composite precursor particle that contains all necessary components (transition metal, alkali metal, and alkaline earth metal) in predetermined ratios and distributions before the sintering process. This preliminary action eliminates the need for separate mixing and addition steps during production, thereby enhancing productivity.
2Productivity
If alkali metal and alkaline earth metal are added separately during firing, then composition control is achieved, but reaction time is long and productivity is low
Solution Approach 1:
The patent pre-mixes and pre-distributes alkali metal and alkaline earth metal precursors within the transition metal precursor particle structure before sintering. This preliminary distribution ensures that all components are in optimal positions for reaction, dramatically reducing the sintering time required while maintaining precise compositional control through the predetermined precursor ratios.
Solution Approach 2:
The patent changes the physical and chemical parameters of the precursor materials by converting them into a composite particle structure where alkali metal and alkaline earth metal precursors are distributed within the transition metal precursor matrix. This parameter change enables faster diffusion and reaction during sintering, reducing reaction time while maintaining composition precision.
3Productivity
If alkali metal and alkaline earth metal are uniformly distributed in precursor particles, then diffusion rate increases and reaction time decreases, but manufacturing complexity increases
Solution Approach 1:
The patent achieves uniform distribution of alkali metal and alkaline earth metal precursors within transition metal precursor particles through a preliminary mixing and granulation process. This preliminary action ensures homogeneous distribution before sintering, enabling high diffusion rates during reaction while the manufacturing process remains manageable through standardized precursor preparation techniques.
4Productivity
If conventional mixing processes are used, then separate materials can be combined, but mixing time is long and production efficiency is low
Solution Approach 1:
The patent merges multiple precursor materials into a single composite precursor particle through a granulation process that combines transition metal precursor, alkali metal precursor, and alkaline earth metal precursor in predetermined ratios. This merging achieves homogeneous distribution of all components within each particle, eliminating the need for long mixing times while ensuring material homogeneity.
Solution Approach 2:
The patent changes the physical state and distribution parameters of the precursor materials by forming a composite particle structure where all components are intimately mixed at the particle level. This parameter change from bulk mixing to particle-level integration achieves homogeneous distribution rapidly, significantly reducing mixing time while maintaining material homogeneity.
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 dramatically increases productivity and improves secondary battery performance by reducing reaction time and enhancing capacity, while allowing for the omission of separate alkali metal and alkaline earth metal addition during firing, thus lowering production costs.
Implementation Method 1
these novel precursor particles have a configuration in which the alkali metal and/or alkaline earth metal are uniformly distributed in the transition metal precursor particles and thus are capable of remarkably improving productivity owing to very high diffusion rate and thus greatly reduced reaction time
Implementation Method 2
enhancing the performance of the secondary battery along with the capacity increase due to high packing density
Data Source
AI summary
Disclosed are novel precursor particles for preparing a cathode active material including transition metal precursor particles containing one or more transition metals, and one or more of an alkali metal and an alkaline earth metal, wherein the alkali metal and the alkaline earth metal are contained in one or more of inner and outer parts of the transition metal precursor particles, and a novel precursor powder including the novel precursor particles.