Fused Lithium Battery Cathode Material Production
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Solution Overview
Problem
There is a need for a lithium-based fused product that is rich in (Li1−aAa)1+x(G1−bJb)y[(XO4)1−dDd]zEe phases, suitable as electrode material for lithium-ion batteries, which can be manufactured in industrial quantities at reduced cost, as existing methods either produce high-cost products with low phase richness or industrially viable products with lower phase content.
Innovation Solution
A fused product with a crystalline part consisting of more than 99.3 wt % of the LAGJXODE phase, achieved through a method involving mixing raw materials, melting above the melting point, controlled cooling, and optional thermal treatment to enhance phase richness, allowing for industrial-scale production at lower costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If solid-phase sintering or mild chemistry is used to produce products rich in (Li1−aAa)1+x(G1−bJb)y[(XO4)1−dDd]zEe phases, then phase richness is improved, but production cost increases significantly
Solution Approach 1:
The invention changes the manufacturing parameters by using fusion at high temperature followed by controlled cooling and thermal treatment. This parameter change transforms the process from solid-phase sintering to fusion-based manufacturing, achieving both high phase richness (>99.3%) and industrial scalability at reduced cost
Solution Approach 2:
The invention exploits phase transitions by melting the starting materials to form a molten state, then controlling the cooling process to achieve solidification with desired crystalline phase formation. The subsequent thermal treatment further controls phase transformation to ensure >99.3% LAGJXODE phase content
2Ease of manufacture
If fusion method is used to produce lithium-based products, then production cost is reduced and industrial scalability is improved, but phase richness in (Li1−aAa)1+x(G1−bJb)y[(XO4)1−dDd]zEe phases decreases
Solution Approach 1:
The invention applies preliminary action by performing thermal treatment after fusion and solidification. This post-processing step is designed to transform the initially formed phases into the desired LAGJXODE phase, ensuring >99.3% phase purity while maintaining the cost advantages of fusion-based manufacturing
Solution Approach 2:
The invention controls phase transitions during cooling and through subsequent thermal treatment. By carefully managing the temperature profile and holding time during thermal treatment, the process promotes formation of the desired crystalline phase while suppressing competing phases, achieving high phase richness through controlled solid-state transformation
3Productivity
If rapid cooling of molten liquid is used to create amorphous structure, then fused product is obtained, but crystalline phase content remains low
Solution Approach 1:
The invention uses periodic action through controlled cooling rates and isothermal holding during thermal treatment. Instead of continuous rapid cooling, the process employs staged cooling with holding periods that allow crystalline phases to nucleate and grow, transforming the amorphous structure into a highly crystalline product with >99.3% LAGJXODE phase
Solution Approach 2:
The invention controls the phase transition from amorphous to crystalline state through thermal treatment. By heating to a specific temperature range and maintaining it for a defined holding time, the process promotes complete crystallization of the amorphous matrix into the desired LAGJXODE phase, achieving both high crystallinity and phase purity
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 method produces a fused product with a high proportion of LAGJXODE phase, enhancing electrochemical performance and making it suitable for lithium-ion battery cathodes, while reducing production costs and maintaining high phase purity.
Implementation Method 1
melting the starting charge until a liquid mass is obtained at a temperature Tlm greater than the melting point Tm of the fused product
Implementation Method 2
cooling until there is complete solidification of said liquid mass, so as to obtain a fused product
Implementation Method 3
thermal treatment of the fused product at a plateau temperature less than the melting point Tm of said fused product and between Tm−800° C., or 500° C. if Tm−800° C. is less than 500° C., and Tm−50° C.
Data Source
AI summary
A method for manufacturing a molten material (the crystallized portion of which consists of a single crystalline phase), includes a) mixing raw materials so as to form a feedstock; b) melting the feedstock until a liquid mass reaches a temperature higher than the melting temperature Tf of the molten material obtained at the end of step e); c) cooling until the liquid mass is completely solidified to obtain a molten material, the amorphous phase of which is constitutes less than 80 wt % thereof; d) optionally crushing/grinding and/or performing selection by particle size on the molten material; e) optionally, heat-treating the molten material at a temperature which is an increment lower than the melting temperature of the molten material and is between Tf−800° C. (or 500° C.) and Tf−50° C., for a period of time in a reducing environment; and f) optionally, crushing/grinding and/or performing selection by particle size on said molten material.