Core-Shell Particle Reactor with Rotor Mixing
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Solution Overview
Problem
The existing methods for manufacturing positive electrode active materials for lithium rechargeable batteries, such as solid-state reactions and co-precipitation, face challenges including non-uniform mixing, high energy dissipation, and difficulty in scaling up reactions, leading to increased manufacturing time and costs, as well as the need for separate shell coating processes.
Innovation Solution
An apparatus and method for manufacturing core-shell particles using a reactor with a non-rotational hollow cylinder and rotor to form a shell on a core by injecting gas, liquid, or solid materials in the presence of a liquid-type solvent, allowing for uniform mixing and coating within a single reactor without separate processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If solid-state reaction method is used to prepare positive electrode active materials, then high temperature reaction can be achieved, but the materials are subjected to physical mixing and grinding resulting in non-uniform mixed state and increased manufacturing time
Solution Approach 1:
The invention changes the physical state of reactants from solid to solution phase, enabling molecular-level mixing through dissolution. The reactants are mixed in aqueous solution where they can diffuse and distribute uniformly, then precipitated to form the final product, eliminating the need for repeated mechanical mixing and grinding steps
Solution Approach 2:
The invention uses liquid medium (aqueous solution) to transport and mix reactants. The hydraulic flow of the solution enables uniform distribution of precursor materials throughout the reaction mixture, achieving homogeneous mixing without mechanical intervention
2Manufacturing precision
If co-precipitation method is used to prepare positive electrode active materials, then uniform mixing can be achieved, but pH, temperature, and stirring conditions must be precisely controlled increasing process complexity
Solution Approach 1:
The invention changes the precipitation mechanism by adjusting pH through buffer solutions or controlled addition of base, rather than maintaining constant pH throughout. Temperature control is simplified by conducting reactions at ambient or mildly elevated temperatures without complex heating/cooling systems
Solution Approach 2:
The invention uses aqueous solution as an intermediary medium to facilitate uniform mixing and controlled precipitation. The liquid phase acts as a carrier that enables gradual reaction and uniform distribution of precursors, simplifying the control of reaction conditions
3Productivity
If CSTR reactor is used for co-precipitation, then continuous mixing can be achieved, but reaction scale cannot be easily increased, devices are expensive, and energy dissipation rate is high
Solution Approach 1:
The invention segments the continuous mixing process into a series of discrete mixing zones along the flow path. Reactants are introduced at different locations and mix progressively as the solution flows through the reactor, eliminating the need for high-energy continuous stirring while maintaining continuous processing
Solution Approach 2:
The invention uses hydraulic flow to drive the reaction process. The continuous flow of aqueous solution through the reactor provides automatic mixing through fluid dynamics, replacing mechanical stirring and significantly reducing energy dissipation while maintaining continuous production capability
4Manufacturing precision
If separate shell coating process is used to form shell on core, then core-shell structure can be formed, but additional process steps and time are required
Solution Approach 1:
The invention merges the core formation and shell coating steps into a single simultaneous process. By introducing core-forming precursors and shell-forming precursors together in the same reaction system, both structures form concurrently during one precipitation reaction, eliminating separate coating operations
Solution Approach 2:
The invention performs preliminary preparation of both core and shell precursors in solution form before the reaction. The precursors are pre-dissolved and mixed in appropriate ratios, so that when precipitation occurs, the core-shell structure forms directly without requiring subsequent coating steps
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 efficient and cost-effective production of core-shell particles with uniform mixing and coating, reducing manufacturing time and costs while allowing for continuous process scalability and eliminating the need for separate shell coating processes.
Implementation Method 1
a reaction device using a Taylor vortex was considered
Implementation Method 2
a heat exchange material moving path formed between an external circumferential side and an interior circumference of the cylinder and providing a moving path of a heat exchange material
Data Source
AI summary
A method of manufacturing core-shell particles comprises: filling a buffer into a rotor, which is extended in a longitudinal direction, and is accommodated so as to be spaced apart from an inner wall side of a non-rotational hollow cylinder extended in a longitudinal direction and then discharging air to outside; rotating the rotor after terminating the filling; forming a core-shell precursor by supplying raw materials from a first storage and a second storage, which comprise a material forming a core, into an interior of the cylinder in which the rotor rotates; supplying a shell material for coating the core to the interior of the cylinder in which a core-type precursor is formed; separating a liquid comprising core-shell particles formed through the supplying into a solid and a liquid; and drying the core-shell particles obtained through the separating.