Oriented NCM Cathode Material via Flow Reactor Parameter Control

Solution Overview

Problem

The existing methods for manufacturing oriented ternary positive electrode precursors for lithium rechargeable batteries require a concentration gradient, leading to high processing costs and the need for multiple inflow tanks, making them inefficient and costly.

Innovation Solution

The method involves changing process variables such as agitation speed, ammonia flow ratio, pH, temperature, and residence time in a flow reactor to impart orientation to the precursor without a concentration gradient, allowing for a more cost-effective and efficient production process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a concentration gradient is used to impart orientation to the precursor, then electrochemical characteristics such as capacity and cycle lifespan are improved, but processing costs increase and multiple inflow tanks are required

Engineering Contradiction:

Improveelectrochemical characteristicsVSAvoidnumber of inflow tanks

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent changes the control parameter from concentration gradient to hydrodynamic conditions (agitation speed, flow rate). By adjusting these parameters in a continuous flow reactor, orientation is achieved without requiring multiple inflow tanks or concentration gradients, thus reducing device complexity while maintaining electrochemical performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the chemical control mechanism (concentration gradient requiring multiple tanks) with a hydrodynamic control mechanism (agitation and flow control in a single reactor). This substitution eliminates the need for complex multi-tank systems while achieving the same orientation effect

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If a concentration gradient is used to impart orientation to the precursor, then electrochemical characteristics such as capacity and cycle lifespan are improved, but production costs increase

Engineering Contradiction:

Improvecycle lifespanVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the control parameter from concentration gradient to hydrodynamic conditions (agitation speed, flow rate). By adjusting these parameters in a continuous flow reactor, orientation is achieved without requiring multiple inflow tanks or concentration gradients, thus reducing device complexity while maintaining electrochemical performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a continuous flow reactor system that allows continuous production of oriented precursors. This continuous operation eliminates the need for batch processing with multiple tanks, reducing both capital expenditure and operational costs while maintaining consistent product quality and cycle lifespan

Inventive Principle:

Principle #20Continuity of useful action

3Shape

If batch-based process is used to realize orientation, then precursor orientation is achieved, but processing time and operational complexity increase

Engineering Contradiction:

Improveprecursor orientationVSAvoidprocessing time

Core Design Contradiction:

ShapeVSLoss of time

Solution Approach 1:

The patent employs a continuous flow reactor system that allows continuous production of oriented precursors. This continuous operation eliminates the need for batch processing with multiple tanks, reducing both capital expenditure and operational costs while maintaining consistent product quality and cycle lifespan

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent uses dynamic hydrodynamic conditions (variable agitation speed, adjustable flow rate) in the continuous reactor to control precipitation and achieve orientation. This dynamic control allows flexible adjustment of processing parameters to optimize both orientation quality and production throughput

Inventive Principle:

Principle #15Dynamics

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

This approach reduces production costs by eliminating the need for precise composition control and multiple tanks, enabling the production of oriented positive electrode materials with improved electrochemical characteristics and cycle lifespan.

Implementation Method 1

performing co-precipitation by using an ammonia solution as a complexing agent and caustic soda as a precipitator

Methodology Applied

Scientific EffectCo-precipitation: Coprecipitation

Data Source

PatentUS11923542B2Positive active material for lithium rechargeable battery, manufacturing method thereof, and lithium rechargeable battery including same positive active material

Publication Date: 2024.03.05 RES INST OF IND SCI & TECH

AI summary

The present disclosure relates to a positive active material for a lithium rechargeable battery, a manufacturing method thereof, and a lithium rechargeable battery including the positive active material, and it provides a positive active material which is a lithium composite metal oxide including nickel, cobalt, and manganese, and either has orientation in a direction of with respect to an ND axis that is equal to or greater than 29% or has orientation in a direction of [120]+[210] with respect to an RD axis that is equal to or greater than 82% in the case of an EBSD analysis with a misorientation angle (Δg) that is equal to or less than 30 degrees.