Spherical Lithium Oxide Particles via Microwave Plasma Processing
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Solution Overview
Problem
Current methods for producing lithium oxide particles for lithium batteries face challenges in achieving optimal particle size, density, and purity, which affect the energy density and performance of these batteries.
Innovation Solution
A microwave-generated plasma process is used to produce spherical lithium oxide particles with controlled particle size and high purity, eliminating the need for additional calcination or purification steps, and enabling the production of non-porous, optimally dense particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to produce lithium oxide particles, then production process is simpler, but particle size, density, and purity are suboptimal
Solution Approach 1:
The patent applies parameter changes by utilizing microwave plasma parameters (temperature, power, gas composition) to transform precursor particles into spherical lithium oxide particles with optimized size (5-500 μm), high density (>2.5 g/cm³), and high purity (>95%). This resolves the contradiction by achieving superior manufacturing precision through controlled parameter changes in the plasma environment.
Solution Approach 2:
The patent employs phase transitions by converting precursor particles through melting and rapid solidification in the microwave plasma field. This phase transition process enables the formation of spherical particles with optimized microstructure, achieving high density and purity while controlling particle size, thus resolving the technical contradiction between process simplicity and product quality.
2Manufacturing precision
If additional calcination or purification steps are added, then particle purity and density improve, but production time and process complexity increase
Solution Approach 1:
The patent merges multiple process steps (calcination, purification, spheroidization) into a single microwave plasma treatment step. The plasma environment simultaneously achieves particle melting, purification, spheroidization, and density optimization, eliminating the need for sequential calcination and purification steps while maintaining high particle quality.
Solution Approach 2:
The patent implements continuous useful action by maintaining particles in the microwave plasma field for a controlled duration, where all necessary transformations (purification, densification, spheroidization) occur continuously in one operation rather than through discrete sequential steps, thereby reducing total production time while achieving high manufacturing precision.
3Quantity of substance
If particle size is reduced to increase energy density, then battery energy density improves, but manufacturing precision and particle uniformity become more difficult to control
Solution Approach 1:
The patent applies spheroidality by forcing precursor particles into spherical shapes through melting and surface tension effects in the microwave plasma field. This spherical morphology, combined with controlled particle size (5-500 μm), optimizes packing density and energy density while maintaining uniform particle characteristics, resolving the contradiction between quantity optimization and manufacturing precision.
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 process results in lithium oxide particles with enhanced sphericity, density, and purity, improving the energy storage capabilities of lithium batteries and making them more environmentally sustainable.
Implementation Method 1
inputting one or more lithium containing precursor powder materials into a microwave generated plasma
Implementation Method 2
contacting the one or more lithium precursor powder materials with the microwave generated plasma
Implementation Method 3
cooling and solidifying the lithium precursor to form one or more spherical lithium oxide particles
Implementation Method 4
cooling and solidifying the lithium precursor to form one or more spherical lithium oxide particles
Data Source
AI summary
The embodiments disclosed herein are directed to systems, methods, and compositions of lithium oxides. In various embodiments of the present disclosure, the systems, methods, and compositions are directed to micron-sized lithium oxide particles that are optimally dense and spherical for use in lithium battery applications.