Recycled Cathode Active Material Surface Area Control for Li Batteries

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Solution Overview

Problem

The high manufacturing costs and environmental impact of lithium secondary batteries are exacerbated by the co-precipitation method used to synthesize lithium composite oxides, which generates wastewater and requires complex processes, necessitating a more efficient and cost-effective method for producing positive electrode active materials.

Innovation Solution

A method involving the reuse of waste positive electrode active materials from end-of-life lithium secondary batteries, where the materials are mixed with a solvent, ground, spray-dried, and thermally treated to produce a lithium composite oxide with similar electrochemical properties to those synthesized by the co-precipitation method.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the co-precipitation method is used to synthesize lithium composite oxide, then the electrochemical properties can be maintained, but the manufacturing cost increases and environmental pollution occurs

Engineering Contradiction:

Improveelectrochemical propertiesVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent recovers and reuses waste positive electrode active material from end-of-life lithium secondary batteries as a raw material for synthesizing new lithium composite oxide. This recycling approach reduces the need for virgin materials and decreases manufacturing costs while maintaining electrochemical performance through controlled surface area optimization

Inventive Principle:

Principle #34Discarding and recovering

2Reliability

If the co-precipitation method is used to synthesize lithium composite oxide, then the electrochemical properties can be maintained, but the process complexity increases and wastewater is generated

Engineering Contradiction:

Improveelectrochemical propertiesVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and utilizes the valuable active material components from waste batteries, separating them from the complex waste battery structure. This extraction approach simplifies the overall process by directly using the recovered material after minimal treatment (grinding and classification) rather than undergoing complex multi-step co-precipitation synthesis

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts waste positive electrode active material, which would otherwise be discarded as harmful waste requiring complex treatment, into a valuable raw material for new battery production. The waste material is ground to control surface area and directly used as precursor, transforming an environmental problem into an economic and environmental benefit

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If the specific surface area of waste positive electrode active material is increased, then the electrochemical properties improve, but the stability decreases

Engineering Contradiction:

Improveelectrochemical propertiesVSAvoidstability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent optimizes the specific surface area parameter of the waste positive electrode active material by controlling the grinding process. By maintaining the specific surface area within the optimal range of 0.5-5.0 m²/g, the patent achieves a balance between improved electrochemical properties (from increased surface area) and maintained stability (by preventing excessive surface area that would cause degradation)

Inventive Principle:

Principle #35Parameter changes

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 manufacturing costs, minimizes environmental pollution, and maintains the electrochemical performance of conventional positive electrode active materials, while promoting resource recycling and sustainability.

Implementation Method 1

preparing a slurry by mixing a waste positive electrode active material and a solvent

Methodology Applied

Scientific EffectMixing:

Implementation Method 2

preparing a precursor by spray-drying the slurry in which the waste positive electrode active material is ground

Methodology Applied

Scientific EffectSpray drying:

Implementation Method 3

obtaining a lithium composite oxide by thermally treating the precursor

Methodology Applied

Scientific EffectThermal treatment: Heat Treatment

Data Source

PatentUS20230290943A1Method of preparing positive electrode active material for lithium secondary battery using waste positive electrode active material

Publication Date: 2023.09.14 ECOPRO BM CO LTD

AI summary

The present invention relates to a method of preparing a positive electrode active material for a lithium secondary battery using a waste positive electrode active material, and more particularly, to a method of preparing a positive electrode active material for a lithium secondary battery using a waste positive electrode active material, which can improve electrochemical properties and stability by controlling the specific surface area of the waste positive electrode active material.