Plasma Spraying Device for Battery Electrode Pre-lithiation
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Solution Overview
Problem
Existing pre-lithiation methods for lithium-ion batteries are complex and difficult to scale for mass production due to the need for multiple steps and the handling of hazardous solvents, and they struggle with depositing materials with low melting points, which can sublime under high energy thermal spraying.
Innovation Solution
A plasma spraying device that uses a plasma generating section to melt and deposit feedstock powders like lithium, aluminum, copper, or silver onto electrodes with a particle diameter of 1 μm to 50 μm, eliminating the need for organic or inorganic coatings and reducing the energy required for melting, thus simplifying the process and enabling the use of low melting point materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high energy thermal spraying is used to melt feedstock, then melting capability is improved, but low melting point materials sublime and cannot be deposited
Solution Approach 1:
The invention changes the energy delivery parameters from high-energy thermal spraying to low-energy plasma spraying, using electric power of 500 W to 10 kW to generate plasma that melts feedstock without causing sublimation of low melting point materials like lithium
Solution Approach 2:
The invention utilizes plasma phase transition (gas to ionized plasma state) to achieve controlled heating that melts feedstock powder particles without exceeding the sublimation temperature, enabling reliable deposition of low melting point materials
2Manufacturing precision
If pre-lithiation is performed using existing spray or coating methods, then lithium doping is achieved, but the process becomes complex requiring multiple steps including pressing and solvent removal
Solution Approach 1:
The invention merges multiple process steps (heating, melting, coating, and drying) into a single plasma spraying operation, eliminating the need for separate pressing and solvent removal steps required in conventional pre-lithiation methods
Solution Approach 2:
The invention extracts and eliminates the complex multi-step process requirements, achieving lithium doping through a simplified single-step plasma spraying method that directly deposits molten lithium powder onto the electrode surface
3Quantity of substance
If existing pre-lithiation methods are used, then lithium can be deposited on electrodes, but handling of specific solvents becomes difficult and mass production is hindered
Solution Approach 1:
The invention replaces the chemical solvent-based removal process with a physical plasma-based heating and evaporation process, eliminating the need for hazardous solvent handling while achieving complete removal of organic/inorganic materials from lithium powder surface
4Ease of operation
If feedstock powder with particle diameter larger than 50 μm is used, then handling is easier, but melting and deposition efficiency decreases
Solution Approach 1:
The invention optimizes the particle size parameter to 1 μm to 50 μm, which balances handling ease with sufficient surface area for efficient plasma heating and melting, enabling rapid deposition while maintaining operational convenience
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 plasma spraying device efficiently deposits metal ions onto electrodes, reducing the complexity of the pre-lithiation process, eliminating the need for solvent handling, and enabling mass production of lithium-ion batteries with improved capacity and efficiency by directly forming a dense, high-aspect-ratio Li film without sublimation of low melting point materials.
Implementation Method 1
a plasma generating section (60) configured to generate a plasma by decomposing a plasma generating gas injected from the nozzle (11) using electric power of 500 W to 10 kW
Implementation Method 2
generate a plasma by decomposing the injected plasma generating gas using electric power of 500 W to 10 kW
Implementation Method 3
spraying the molten lithium powder R1 toward a surface of a substrate W to form an Li film F1 on the surface of the substrate W
Implementation Method 4
by melting the feedstock powder by the plasma generated in the enclosed region
Implementation Method 5
depositing the feedstock powder on a workpiece by melting the feedstock powder by the plasma generated in the enclosed region
Data Source
AI summary
There is provision of a plasma spraying device including a supplying section configured to convey feedstock powder with a plasma generating gas, and to inject the feedstock powder and the plasma generating gas from an opening of a tip; a plasma generating section configured to generate a plasma by decomposing the injected plasma generating gas using electric power of 500 W to 10 kW; and a chamber causing the supplying section and the plasma generating section to be an enclosed region, which is configured to deposit the feedstock powder on a workpiece by melting the feedstock powder by the plasma generated in the enclosed region. The feedstock powder is any one of lithium (Li), aluminum (Al), copper (Cu), silver (Ag), and gold (Au). A particle diameter of the feedstock powder is between 1 μm and 50 μm.