Single-Crystal Cathode Material Without Jet Milling
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Solution Overview
Problem
Existing methods for producing single-crystal cathode materials, such as amorphous precursor sintering and jet milling, are complex, costly, and inefficient, leading to uneven ion precipitation and increased production costs due to the need for jet milling and cyclone separation.
Innovation Solution
A method using a polycrystalline precursor to produce single-crystal cathode materials through two sinter-treating processes without jet milling, involving mixing and ball milling with a lithium source and a coating source with a large ionic radius, followed by controlled sintering at specific temperatures and times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If amorphous precursor sintering method is used to prepare single-crystal cathode materials, then single-crystal structure is achieved, but the process becomes complex and costly with uneven ion precipitation
Solution Approach 1:
Instead of using amorphous precursor to achieve single-crystal structure, the patent inverts the approach by using polycrystalline precursor with controlled particle size (5-20 μm) and specific morphology to directly obtain single-crystal cathode materials through sintering, eliminating the need for complex co-precipitation control
Solution Approach 2:
The patent changes key parameters including precursor particle size (5-20 μm), sintering temperature (900-1000°C), and sintering time (20-40 hours) to transform polycrystalline precursor into single-crystal cathode materials, achieving uniform ion distribution without complex process control
2Manufacturing precision
If jet milling method is used to obtain single-crystal cathode materials, then single-crystal structure is achieved, but fine powders are produced requiring cyclone separation which increases production cost
Solution Approach 1:
The patent extracts and eliminates the jet milling step from the traditional process, using polycrystalline precursor sintering to directly produce single-crystal cathode materials with appropriate particle size, thereby removing the need for cyclone separation and reducing production costs
Solution Approach 2:
The patent performs preliminary control of precursor particle size (5-20 μm) and morphology before sintering, which prevents the formation of fine powders during processing and eliminates the need for subsequent jet milling and cyclone separation operations
3Device complexity
If polycrystalline precursor is used to prepare single-crystal cathode materials through two-stage sintering, then process complexity is reduced and costs are lowered, but single-crystal structure must be achieved
Solution Approach 1:
The patent divides the sintering process into two stages: first sintering (900-1000°C, 20-40 hours) to form intermediate structure, then second sintering (900-1000°C, 10-20 hours) with source A to achieve single-crystal structure, making the complex transformation manageable and controllable
Solution Approach 2:
The patent uses source A (oxides or carbonates of Nb, Sr, W with large ionic radius) as an intermediary during the second sintering stage to facilitate the transformation from polycrystalline to single-crystal structure, enabling precise control of the crystallization process
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 simplifies the process, reduces costs, and enhances the compatibility of producing single-crystal cathode materials by eliminating the need for jet milling and cyclone separation, resulting in improved particle dispersion and reduced adhesion.
Implementation Method 1
mixing and ball milling a lithium source with a nickel-cobalt-manganese polycrystalline precursor
Implementation Method 2
performing a first sinter-treating to obtain a first main material, wherein sinter temperature is 650 to 950°C and sinter time is 15- 30 hours
Implementation Method 3
performing a second sinter-treating to prepare a single-crystal cathode material
Implementation Method 4
mixing and ball milling the first main material with source A and then performing a second sinter-treating to prepare a single-crystal cathode material, wherein source A is oxides or carbonates with large ionic radius
Data Source
Figure 1~2
Figure 3
AI summary
The present application provides a single-crystal cathode material and preparing method thereof. The method involves mixing and ball milling a lithium source with a nickel-cobalt-manganese precursor and then performing a first sintering treatment to obtain the first main material, wherein sintering temperature is 650 to 950°C and sintering time is 15 to 30 hours. The first main material is then mixed and ball-milled with source A and performing a second sintering treatment to prepare the single-crystal cathode material, wherein sintering temperature is 650~ 950°C and sintering time is 5~15 hours. The present application uses a polycrystalline precursor to directly prepare a single-crystal cathode material without jet milling, making the process simple and cost-effective, and greatly enhancing the compatibility of the process.