Filter Baffle Reactor for Uniform Cathode Precursor Particles

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Solution Overview

Problem

Existing methods for producing positive electrode active material precursors for lithium secondary batteries face challenges in achieving uniform particle size, shape, and distribution while maintaining high productivity, due to limitations in reactor design such as continuous stirred-tank reactors (CSTR) and batch reactors.

Innovation Solution

An apparatus incorporating a filter type baffle that integrates filtration and baffling functions, allowing continuous filtration and concentration of the reaction solution, which improves the uniformity and productivity of the positive electrode active material precursor by ensuring consistent particle size and shape distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a continuous stirred-tank reactor (CSTR) is used to introduce and coprecipitate raw materials continuously, then productivity is improved, but particle size uniformity deteriorates due to deviations in residence time and reaction time

Engineering Contradiction:

ImproveproductivityVSAvoidparticle size uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The reactor is divided into multiple compartments (first reaction compartment, second reaction compartment, filtration compartment) that are connected in series. This segmentation allows the reaction process to be divided into distinct stages, ensuring that all particles undergo the same sequential steps with controlled residence times, thereby improving particle size uniformity while maintaining continuous operation for high productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The apparatus performs preliminary filtration of the reaction mixture before the coprecipitation reaction is complete. By filtering the mixture in the filtration compartment during the reaction process, particles are removed from the liquid phase early, ensuring uniform residence time for all particles and preventing size variations that would occur in continuous coprecipitation without intermediate filtration.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If a batch reactor is used to produce positive electrode active material precursor, then particle size uniformity is improved, but productivity deteriorates due to discontinuous operation

Engineering Contradiction:

Improveparticle size uniformityVSAvoidproductivity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The apparatus enables continuous operation by maintaining steady flow of raw materials through the reactor compartments and continuously filtering and discharging the reaction mixture. This continuous action eliminates the stopping and starting inherent in batch processes, maintaining high productivity while the segmented compartment design ensures uniform particle formation throughout the continuous process.

Inventive Principle:

Principle #20Continuity of useful action

3Device complexity

If filtration and baffling functions are separated in the reactor, then device complexity is reduced, but filtration flow rate is limited due to spatial constraints

Engineering Contradiction:

Improvedevice complexityVSAvoidfiltration flow rate

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The filtration function is merged with the baffling structure by integrating a filter into the baffle component. This combination allows the baffle to serve dual purposes: directing fluid flow and filtering the reaction mixture simultaneously. The integrated design overcomes spatial constraints that would limit filtration flow rate if filtration were performed by a separate component, while avoiding the complexity of adding multiple independent filtration systems.

Inventive Principle:

Principle #5Merging (Combining)

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

The integrated filter baffle apparatus enhances the quality and productivity of the positive electrode active material precursor by ensuring uniform particle size, shape, and distribution, while overcoming spatial constraints that limit filtration flow rates in traditional setups.

Implementation Method 1

a filter type baffle being inserted into the reactor and comprising the filter

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

a stirrer being inserted into the reactor and stirring the reaction solution

Methodology Applied

Scientific EffectStirring: Stirring

Data Source

PatentUS12064742B2Apparatus and method for producing positive electrode active material precursor

Publication Date: 2024.08.20 LG CHEM LTD

AI summary

Provided is an apparatus for producing a positive electrode active material precursor. The apparatus includes: a reactor into which a reaction solution is introduced; a stirrer being inserted into the reactor and stirring the reaction solution; and a filter type baffle being inserted into the reactor and including a filter.