Battery Electrode Thermal Shock Recycling for Impurity Removal
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Solution Overview
Problem
Existing methods for recycling battery electrodes, particularly graphite from negative electrodes, suffer from low efficiency and fail to completely remove complex organic or inorganic impurities, while positive electrodes often lose metals during recycling, leading to inefficient reuse of materials.
Innovation Solution
A high-temperature, short-duration thermal shock process is applied to battery electrodes to remove impurities such as solid electrolyte interphase, binder, and isolated metals, effectively regenerating the electrode material for reuse by subjecting the electrodes to temperatures of at least 1000 K for 10 seconds or less, with rapid heating and cooling rates, and potentially reintroducing metals into the positive electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional recycling methods (hydrometallurgical or pyrometallurgical processes) are used, then metals can be recovered from positive electrodes, but graphite from negative electrodes is burned or disposed and impurities remain on electrode materials
Solution Approach 1:
The invention changes the thermal parameters by applying ultrafast heating (10^3-10^6 K/s) to reach extreme temperatures (2000-4000 K) for very short durations (microseconds to seconds). This parameter transformation allows graphite to be regenerated rather than destroyed, converting the thermal treatment from destructive combustion to regenerative purification that removes impurities while preserving the graphite structure.
Solution Approach 2:
The invention employs periodic pulsed heating cycles where electrode materials are subjected to repeated ultrafast thermal shocks. Each pulse removes a portion of impurities (SEI, binder, solvent residues) while the brief duration prevents graphite degradation. Multiple cycles can be applied to achieve progressive purification while maintaining graphite integrity.
2Reliability
If high-temperature processing is applied to remove impurities, then purification efficiency improves, but processing time increases and energy consumption rises
Solution Approach 1:
The invention rushes through the high-temperature treatment phase by applying ultrafast heating that reaches 2000-4000 K in microseconds to seconds. The process skips the prolonged high-temperature exposure that would consume energy and time, achieving impurity removal in a brief thermal shock that prevents energy waste while maintaining effective purification.
Solution Approach 2:
The invention exploits phase transitions of impurities during ultrafast heating. Impurities such as binder, solvent residues, and SEI layers undergo rapid vaporization or decomposition at the extreme temperatures achieved during the pulsed heating, while the brief duration prevents the graphite itself from undergoing destructive phase changes or combustion.
3Loss of substance
If conventional pyrometallurgical processes are used, then metals can be recovered, but graphite is burned and material is lost
Solution Approach 1:
The invention creates an inert or reducing atmosphere during the ultrafast heating process to prevent oxidation of graphite. By controlling the ambient environment and using extremely short heating durations, the process avoids the oxidative combustion that occurs in conventional pyrometallurgical treatments, preserving the graphite carbon structure while still removing impurities through thermal decomposition.
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 method efficiently recycles electrodes by removing impurities and improving the structural integrity of graphite, enhancing its crystallinity and maintaining or improving battery performance, allowing for the effective reuse of recycled materials in new batteries.
Implementation Method 1
the recycling involves subjecting electrode material to a high-temperature, short-duration thermal shock
Implementation Method 2
The thermal shock can be achieved, for example, by a pulsed heating profile
Implementation Method 3
a cooling rate of at least 10³ K/second following the time period
Data Source
AI summary
Degraded electrode material from a used battery can be recycled by subjecting to a thermal shock. The degraded electrode material can have impurities resulting from charge/discharge cycling of the battery. The thermal shock can have a temperature of at least 1000 K for a time period of 10 seconds or less, for example, less than or equal to 1 second. The thermal shock can also include a heating rate of at least 103 K/second preceding the time period and a cooling rate of at least 103 K/second following the time period. The subjecting to the thermal shock regenerate the electrode material, for example, by removing impurities from the electrode material and/or replenishing metal ions within the electrode material.