Solid Sodium Electrolyte Gas-Phase Conversion With Reusable Powder Pellets
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Solution Overview
Problem
Existing methods for producing sodium solid electrolytes through vapor-phase conversion face challenges such as difficulty in reusing surrounding powder, requiring additional processes to remove residual powder, and limitations to single reactor production, leading to high manufacturing costs.
Innovation Solution
A method involving the preparation of a sintered body and surrounding powder pellets, laminating them alternately to form a stack, and heat-treating to convert alpha-alumina into beta-alumina, using a pre-sintered body of alpha-alumina and yttria-stabilized zirconia, with the surrounding powder pellets being in a molded form to facilitate reuse and multiple production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If surrounding powder is used in powder form for vapor-phase conversion, then the reaction can proceed, but the powder sticks to the sintered body and requires additional removal processes
Solution Approach 1:
The invention changes the physical state parameter of the surrounding powder from loose powder form to compact pellet form. This parameter change prevents the powder from sticking to the sintered body during vapor-phase conversion, eliminating the need for additional removal processes and simplifying the manufacturing procedure
Solution Approach 2:
The surrounding powder is segmented and compacted into discrete pellets that can be easily separated from the sintered body after reaction. This segmentation allows for straightforward removal by simple physical separation rather than requiring complex removal processes
2Productivity
If surrounding powder is used in powder form, then vapor-phase conversion can occur, but the used powder cannot be reused and must be discarded
Solution Approach 1:
The invention enables recovery and reuse of the surrounding powder by compacting it into pellets after the vapor-phase conversion process. These recovered pellets can be reused in subsequent production cycles, reducing material waste and improving production efficiency
Solution Approach 2:
By changing the physical form from loose powder to compact pellets, the surrounding powder becomes reusable. The pellet form maintains its structural integrity through multiple use cycles, allowing the same material to be reused without significant degradation
3Reliability
If one sintered body is processed at a time in one reactor, then the reaction conditions can be controlled, but the production capacity is limited
Solution Approach 1:
The invention segments the production process by using multiple small reactors instead of one large reactor. Each reactor processes one sintered body with controlled reaction conditions, while the overall production capacity is increased by operating multiple reactors in parallel or sequence
Solution Approach 2:
The reactor design is made universal by creating a standardized unit that can be replicated and reused. The same reactor configuration can process multiple sintered bodies by being used repeatedly, effectively increasing production capacity while maintaining consistent process control
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 process steps, manufacturing time, and costs by enabling the reuse of surrounding powder and allowing multiple production of sodium solid electrolytes with improved ionic conductivity and mechanical strength.
Implementation Method 1
heat-treating the stack to subject the sintered body to vapor-phase conversion into beta-alumina
Implementation Method 2
reacts it with sodium oxide (Na2O) or the like to transform alpha-alumina into beta-alumina
Data Source
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AI summary
A method for producing a sodium solid electrolyte according to an embodiment of the present invention comprises the steps of: (a) preparing sintered bodies for beta-alumina production and powder pellets comprising a sodium source (or powder packs); (b) laminating the sintered bodies and the powder pellets comprising a sodium source (or powder packs) in alternation to prepare a stack; and (c) heat-treating the stack to subject the sintered bodies to vapor-phase conversion, wherein the powder pellets (or powder packs) may be molded bodies of powder containing a sodium source.