Single-Step Calcination for Ti-Nb-O Active Material Carbon Coating
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Solution Overview
Problem
The existing methods for manufacturing active materials for batteries, such as titanium niobium oxide, require complex and costly processes involving multiple calcination steps to coat the material with carbon, which complicates the production and reduces efficiency.
Innovation Solution
A method is developed to manufacture active materials by mixing titanium, niobium, and a carbon source with an element M, followed by calcination in a mixed atmosphere of nitrogen and oxygen or argon with an oxygen concentration of 5-15%, allowing for a single calcination step and forming a carbon-including phase on the surface of the composite oxide particles, thereby improving charge and discharge properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple calcination steps are used to coat the material with carbon, then the carbon coating is achieved, but the production process becomes complex and costly
Solution Approach 1:
The patent combines the carbon coating process with the main calcination step by adding a carbon source to the precursor mixture before calcination. This merging of operations eliminates the need for separate coating steps, reducing process complexity while maintaining effective carbon coating on the active material particles
Solution Approach 2:
The carbon source is incorporated into the precursor mixture before the calcination step, performing the carbon coating action in advance during the main material synthesis process. This preliminary incorporation of carbon ensures that the coating forms simultaneously with the active material structure, avoiding subsequent complex coating operations
2Manufacturing precision
If multiple calcination steps are used to coat the material with carbon, then the carbon coating is achieved, but production efficiency is reduced
Solution Approach 1:
The patent merges the carbon coating operation with the main calcination step into a single process operation. By incorporating the carbon source in the precursor mixture and performing one calcination step, the process eliminates multiple sequential operations, thereby显著提高 production efficiency while maintaining coating quality
Solution Approach 2:
The carbon coating action continues throughout the single calcination step rather than being performed in separate discrete steps. The carbon source decomposes and deposits on the particles continuously during the calcination process, maintaining productive action throughout the entire heating period and eliminating idle time between steps
3Device complexity
If titanium and niobium compounds are mixed with carbon source and element M, then a single calcination step is achieved, but control of reduction reactions becomes more difficult
Solution Approach 1:
The patent carefully controls the oxygen concentration parameter in the calcination atmosphere, maintaining it within the specific range of 5-15%. This parameter control prevents excessive reduction of titanium and niobium while allowing sufficient carbon coating, resolving the contradiction between process simplicity and reduction control reliability
Solution Approach 2:
The patent uses a composite precursor mixture containing titanium compound, niobium compound, carbon source, and element M in specific proportions. This composite formulation ensures that the multi-component system undergoes controlled reactions during calcination, maintaining reliability of reduction control while achieving process simplification through single-step processing
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 method simplifies the production process, enhances energy density and rate properties of the active material, and reduces resistance, resulting in a nonaqueous electrolyte battery with improved performance.
Implementation Method 1
calcination in a mixed atmosphere of nitrogen and oxygen or argon with an oxygen concentration of 5-15%
Implementation Method 2
calcining the precursor... calcination takes place in a mixed atmosphere including nitrogen and oxygen, or argon and oxygen
Data Source
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AI summary
According to an embodiment, a method of manufacturing an active material is provided. The active material includes particles of a composite oxide of the general formula Ti1±xNb2±yMzO7-δ and a carbon-including phase. Here, 0 ≤ x ≤ 0.15, 0 ≤ y ≤ 0.3, 0.01 < z ≤ 0.2, and 0 < δ < 0.3. M is at least one of Mg, Fe, Ni, Co, W, Ta, and Mo. The manufacturing method includes preparing a mixture by mixing in a liquid, a compound including Ti, a compound including Nb, a carbon source, and a compound including an element M, obtaining a precursor from the mixture, and calcining the precursor. The calcination is performed in a mixed atmosphere including nitrogen and oxygen, or argon and oxygen, with an oxygen concentration of 5% to 15%.