Electrode Scrap Recycling by Dry Milling and Sieving
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Solution Overview
Problem
The recycling of valuable metals from lithium secondary battery electrode scraps is inefficient, leading to high costs and environmental concerns due to the complexity and additional expenses of conventional methods, which often require chemical processes and result in performance degradation.
Innovation Solution
A method involving dry milling and sieving of electrode scraps to separate active material layer flakes from current collector fragments, using a series of sieves with decreasing mesh sizes to obtain reusable particles, which can be directly used to fabricate new electrodes without additional treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional chemical recycling methods are used to recover active material from electrode scraps, then metal extraction can be achieved, but the process complexity increases and performance degradation occurs
Solution Approach 1:
The patent replaces chemical recycling methods with a purely mechanical approach using dry milling and classification equipment. The mill breaks down electrode scraps into particles, and the classifier separates active material particles from current collector fragments based on size differences, eliminating the need for chemical processes while maintaining recovery efficiency
Solution Approach 2:
The recycling process is divided into two distinct stages: dry milling to fragment the electrode scrap material, and classification to separate active material from current collector based on particle size. This segmentation allows each stage to be optimized independently and simplifies the overall process
2Loss of substance
If conventional chemical recycling methods are used, then active material can be recovered, but additional costs and performance degradation occur
Solution Approach 1:
The patent replaces chemical recycling methods with a purely mechanical approach using dry milling and classification equipment. The mill breaks down electrode scraps into particles, and the classifier separates active material particles from current collector fragments based on size differences, eliminating the need for chemical processes while maintaining recovery efficiency
Solution Approach 2:
The patent controls particle size parameters through the classification process to ensure that active material particles are separated at optimal sizes that maintain their electrochemical performance. By adjusting classification mesh sizes and cutting speeds, the process preserves the structural integrity and performance characteristics of the recovered active material
3Ease of manufacture
If simple dry milling is used without classification, then processing is simplified, but separation of active material from current collector is incomplete
Solution Approach 1:
The recycling process is divided into two distinct stages: dry milling to fragment the electrode scrap material, and classification to separate active material from current collector based on particle size. This segmentation allows each stage to be optimized independently and simplifies the overall process
Solution Approach 2:
The patent controls particle size parameters through the classification process to ensure that active material particles are separated at optimal sizes that maintain their electrochemical performance. By adjusting classification mesh sizes and cutting speeds, the process preserves the structural integrity and performance characteristics of the recovered active material
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 simplifies the recycling process, reduces costs, and maintains the performance of lithium secondary batteries by allowing the direct reuse of active material layer flakes without altering their composition, thus enhancing recycling ratios and electrode properties.
Implementation Method 1
a pin-mill, which rotates in a counter-direction to the rotor, is provided between the rotor and the stator
Implementation Method 2
screening active material layer flakes from current collector fragments in the milled products by sieving the milled products
Data Source
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AI summary
Provided are a reuse method of electrode scrap and a method of fabricating a recycled electrode using the same. The reuse method of electrode scrap of the present disclosure includes (a) dry milling electrode scrap remaining after punching an electrode sheet including an active material layer on a current collector to obtain milled products; and (b) screening active material layer flakes from current collector fragments in the milled products by sieving the milled products, and collecting the screened active material layer flakes to obtain reusable particles.