Mn-Ni (Oxy)Hydroxide Coprecipitation for Dense Cathode Packing
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Solution Overview
Problem
Lithium-ion batteries with high-manganese cathode active materials suffer from limited volumetric energy density and poor packing properties, leading to reduced cycle life and capacity loss.
Innovation Solution
A process for producing spherical (oxy)hydroxides of manganese and nickel, using a coaxial mixer to control pH and precipitation conditions, followed by drying, to create a precursor with enhanced packing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high-manganese cathode active materials are used, then energy density is improved, but volumetric energy density and packing properties deteriorate
Solution Approach 1:
The patent applies spherical particle morphology to the cathode active material precursor. The co-precipitation process produces spherical particles with diameter of 2-15 μm, which pack more efficiently than irregular particles. This spherical shape directly addresses the volumetric energy density problem while maintaining high energy density through optimized metal composition (at least 50 mol-% manganese with nickel and other transition metals).
2Ease of manufacture
If conventional mixing methods are used, then manufacturing simplicity is maintained, but particle morphology and packing properties deteriorate
Solution Approach 1:
The patent introduces a coaxial mixer as an intermediary device between the metal salt solutions and precipitating agent. This specialized mixing apparatus creates a controlled precipitation environment that produces spherical particles. The coaxial mixer mediates the interaction between solutions (α) containing transition metal salts and solution (β) containing alkali metal hydroxide, enabling simple manufacturing with improved particle morphology.
Solution Approach 2:
The patent controls specific process parameters during co-precipitation: pH value in the range of 9.5-10.3, temperature of 20-80°C, and precise metal ratios (Ni:Mn = 1:2 to 1:4). These parameter changes transform the precipitation process to produce spherical particles with enhanced packing properties while maintaining manufacturing feasibility.
3Device complexity
If irregular shaped particles are used, then manufacturing complexity is reduced, but packing properties and volumetric energy density deteriorate
Solution Approach 1:
The patent systematically produces spherical particles through controlled co-precipitation using a coaxial mixer. The spherical morphology (diameter 2-15 μm) provides superior packing properties and volumetric energy density compared to irregular particles, while the process remains relatively simple and suitable for industrial manufacturing.
4Device complexity
If pH is not controlled during precipitation, then process complexity is reduced, but precipitate quality and composition homogeneity deteriorate
Solution Approach 1:
The patent implements pH control during the co-precipitation process to ensure consistent composition and spherical particle formation. By monitoring and adjusting pH to the range of 9.5-10.3, the process achieves homogeneous metal distribution and reliable particle morphology, with the pH control acting as a feedback mechanism to maintain quality standards.
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 cathode active materials with improved volumetric energy density and discharge performance, enhancing the energy storage capacity and cycle life of lithium-ion batteries.
Implementation Method 1
combining solutions (α) and (β) at a pH value in the range of from 9.5 to 10.3, wherein such step (b) is carried out using at least one coaxial mixer... thereby precipitating an (oxy)hydroxide of TM
Implementation Method 2
recovering and drying said (ox)hydroxide of TM
Data Source
AI summary
Disclosed herein is a process for making an (oxy)hydroxide of TM where TM refers to metals of which at least 97 mol-% are transition metals and where TM includes manganese and nickel, and where at least 50 mol-% of TM are manganese, the process including the steps of:(a) providing at least one aqueous solution (α) of water-soluble salts of such metals and an aqueous solution (β) including alkali metal hydroxide selected from the group consisting of NaOH and KOH,(b) combining solutions (α) and (β) at a pH value in the range of from 9.5 to 10.3, where such step (b) is carried out using at least one coaxial mixer including two coaxially orientated pipes through which an aqueous solution (β) and an aqueous solution of (α) are introduced into a stirred vessel, thereby precipitating an (oxy)hydroxide of TM, and(c) recovering and drying the (oxy)hydroxide of TM.