Induction Heating for Battery Electrode Delamination and Recycling

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Solution Overview

Problem

Current recycling methods for lithium-ion battery electrodes require the use of toxic solvents and high energy, leading to low peeling-off efficiency, complex processes, and high costs, while also damaging the active materials and generating secondary waste.

Innovation Solution

A solvent-free, high-frequency induction heating process that selectively heats the interface between the active materials and current collectors, exploiting the difference in thermal expansion coefficients to achieve efficient delamination without altering the materials' properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional recycling methods using toxic solvents and high energy are employed, then active materials can be recovered, but the process complexity increases, costs increase, and the active materials are damaged

Engineering Contradiction:

Improverecovery of active materialVSAvoidprocess complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent extracts and removes the binder material from the electrode structure through selective dissolution, separating it from the active material and current collector. This extraction approach simplifies the overall recycling process by eliminating the need for complex multi-step procedures while effectively recovering intact active materials.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a selective solvent as an intermediary substance that facilitates the separation of binder from active material. This mediator selectively dissolves the binder while leaving the active material intact, enabling simple filtration and recovery without complex processing equipment.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If conventional recycling methods using toxic solvents and high energy are employed, then active materials can be recovered, but energy consumption increases and greenhouse gas emissions increase

Engineering Contradiction:

Improverecovery of active materialVSAvoidenergy consumption

Core Design Contradiction:

Quantity of substanceVSUse of energy by moving object

Solution Approach 1:

The patent employs a disposable selective solvent that can be used in a single pass to dissolve the binder. This approach eliminates the need for energy-intensive heating and multiple processing cycles, significantly reducing energy consumption while effectively recovering active materials.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Quantity of substance

If conventional recycling methods using toxic solvents and high energy are employed, then active materials can be recovered, but peeling-off efficiency decreases and active materials are damaged

Engineering Contradiction:

Improverecovery of active materialVSAvoidintegrity of active material

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the chemical parameters of the system by introducing a selective solvent that alters the solubility characteristics of the binder. This parameter change enables selective removal of the binder at ambient conditions, preserving the integrity of the active material without requiring high energy input that would cause damage.

Inventive Principle:

Principle #35Parameter changes

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 recovers high-purity electrode materials with minimal energy consumption and reduced greenhouse gas emissions, enabling direct recycling and reuse of active materials with performance comparable to virgin materials.

Implementation Method 1

heating, by induction, the feedstock

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 2

The different heating rates of the components drive the delamination

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Implementation Method 3

exploiting the difference in thermal expansion coefficients to achieve efficient delamination

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20250269637A1Systems and methods for electrode delamination by induction heating

Publication Date: 2025.08.28 UCHICAGO ARGONNE LLC

AI summary

A method includes providing a feedstock. The feedstock includes a first active material disposed on a first current collector and a second active material disposed on a second current collector. The method includes heating, by induction, the feedstock above a first temperature for a first period of time. The method includes delaminating the first active material from the first current collector during the first period of time. The method includes heating, by induction, the feedstock above a second temperature, which is greater than the first temperature, for a second period of time subsequent to the first period of time. The method includes delaminating the second active material from the second current collector during the second period of time.