Sheet Pseudo-Boehmite Production Using Couette-Taylor Vortex Flow
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Solution Overview
Problem
Conventional methods for producing sheet phase pseudo-boehmite are inefficient due to the inability to create a high temperature-high pressure atmosphere, leading to prolonged reaction times and difficulties in achieving a small thickness, which is necessary for improving the thermal stability of ceramic coated separators in batteries.
Innovation Solution
A method utilizing a Taylor reactor with controlled conditions, including a Couette-Taylor vortex flow, where an organic acid is added to an aluminum precursor solution, which is then processed at specific temperatures and pressures to produce sheet phase pseudo-boehmite efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a batch reactor is used to produce sheet phase pseudo-boehmite, then the pseudo-boehmite can be produced under basic conditions, but the reaction time is prolonged to about 24 hours and the production process is inefficient
Solution Approach 1:
The patent changes the pH parameter from basic conditions to acidic conditions (pH 2-6), which fundamentally alters the reaction pathway and enables sheet phase formation with much shorter reaction times (1-20 hours) while maintaining the desired sheet morphology
Solution Approach 2:
The patent replaces the conventional batch reactor mechanical system with a Taylor reactor that utilizes Couette-Taylor vortex flow, creating intense mixing and heat transfer that accelerates the reaction rate and enables efficient sheet phase production
2Manufacturing precision
If a batch reactor is used to produce sheet phase pseudo-boehmite, then the pseudo-boehmite can be produced, but the facility cannot create a high temperature-high pressure atmosphere
Solution Approach 1:
The patent replaces the batch reactor with a Taylor reactor that utilizes Couette-Taylor vortex flow, creating intense mixing and heat transfer that enables efficient reaction at high temperatures (100-300°C) and pressures (1-100 bar) that were unattainable in conventional batch reactors
3Shape
If pseudo-boehmite is produced under basic conditions to achieve sheet phase, then the sheet phase can be obtained, but the thickness is not sufficiently small
Solution Approach 1:
The patent changes the pH parameter from basic to acidic conditions (pH 2-6), which fundamentally alters the crystal growth mechanism to produce sheet phase pseudo-boehmite with sufficiently small thickness (1-10 nm) that was not achievable under basic conditions
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 significantly reduces reaction time to produce sheet phase pseudo-boehmite, allowing for improved thermal stability and reduced weight of ceramic coated separators, enhancing battery safety and efficiency.
Implementation Method 1
supplying a product from the process of a) into a Taylor reactor, wherein a pressure of the Taylor reactor is 1 to 100 bar while producing the sheet phase pseudo-boehmite
Data Source
AI summary
A method for producing a sheet phase pseudo-boehmite. The method includes: a) putting an organic acid into an aqueous solution in which an aluminum precursor is dispersed; and b) putting a product from the process of a) into a Taylor reactor, wherein a pressure of the Taylor reactor is 1 to 100 bar.