Blended Ternary Cathode Material Sintering With Zoned Sagger Loading
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Solution Overview
Problem
Existing large-and-small-particle blending processes for lithium battery positive-electrode materials are complex, time-consuming, and limited by low productivity and high costs due to separate sintering requirements, leading to non-uniform primary particles and reduced electrical performance.
Innovation Solution
A method involving presintering of large and small particle precursors with lithium sources and additives, followed by compacting and puncturing to form to-be-sintered blocks, which are then loaded into a sagger for primary sintering using regional or layered distribution modes that exploit temperature differences in the kiln to improve uniformity and electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate sintering is performed for large particles and small particles, then the preparation process can be completed, but the preparation time becomes long and the process becomes complex
Solution Approach 1:
The patent combines the sintering processes for large particles and small particles into a single simultaneous sintering operation. By placing both particle sizes in the same sagger and sintering them together under controlled temperature gradients, the process eliminates the need for separate sintering steps, thereby reducing preparation time and process complexity while maintaining particle uniformity through the temperature distribution within the sagger.
2Manufacturing precision
If separate sintering is performed for large particles and small particles, then the preparation can be completed, but the productivity is limited by apparent density and thus remains low
Solution Approach 1:
The patent merges the processing of large and small particles into a single batch operation within one sagger. This allows both particle sizes to be processed simultaneously, doubling the effective throughput per sintering cycle compared to separate processing, thereby significantly improving productivity while maintaining particle uniformity through controlled temperature distribution.
Solution Approach 2:
The patent introduces spatial dimensionality into the sintering process by utilizing vertical layering within the sagger. Large particles are placed in the lower layer and small particles in the upper layer, allowing both to be sintered simultaneously at different temperature zones. This three-dimensional arrangement maximizes space utilization and enables high-volume processing in a single operation, thereby improving productivity.
3Manufacturing precision
If separate sintering is performed for large particles and small particles, then the preparation can be completed, but the preparation cost becomes high
Solution Approach 1:
The patent combines the sintering operations for large and small particles into a single process step using one sagger. This eliminates the need for multiple separate sintering cycles, reducing energy consumption, equipment usage time, and operational costs. The simultaneous processing of both particle sizes in one batch significantly lowers preparation costs while maintaining particle uniformity through controlled temperature distribution within the sagger.
4Productivity
If conventional loading mode is used in primary sintering, then the sintering can be performed, but the uniformity of primary particles deteriorates and electrical performance decreases
Solution Approach 1:
The patent applies local quality by creating different thermal environments within different regions of the sagger. By placing large particles in the lower layer and small particles in the upper layer, each particle size experiences an optimized temperature zone during sintering. This spatial differentiation of thermal conditions ensures uniform particle formation for both sizes, improving particle uniformity and electrical performance while maintaining sintering efficiency.
Solution Approach 2:
The patent transitions from a conventional single-layer loading mode to a two-layer vertical loading mode within the sagger. This three-dimensional arrangement allows simultaneous optimization of temperature exposure for different particle sizes, with large particles in the lower (cooler) zone and small particles in the upper (hotter) zone. This dimensional change enables both high sintering efficiency and superior particle uniformity.
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 enhances the uniformity of primary particles and improves the electrical performance of the blended ternary positive-electrode material, increasing productivity and reducing preparation costs while maintaining high sintering quality.
Implementation Method 1
loading the first to-be-sintered material block and the second to-be-sintered material block into a sagger together for primary sintering, wherein a loading mode for the primary sintering is selected from a first loading mode and a second loading mode... exploit temperature differences in the kiln
Implementation Method 2
mixing a large-particle-size precursor with a lithium source, performing presintering to obtain a first presintered material, mixing a small-particle-size precursor with a lithium source, and performing presintering to obtain a second presintered material
Data Source
AI summary
The present disclosure discloses a blended ternary positive-electrode material, a preparation method thereof and a lithium ion battery, and relates to the field of lithium battery technologies. A temperature-sensitive precursor type material is taken as a raw material, a large-particle precursor, a small-particle precursor and lithium sources are presintered to obtain a first presintered material and a second presintered material, presintered materials and binders are then mixed, compacted and punctured to obtain a first to-be-sintered material block and a second to-be-sintered material block, the first to-be-sintered material block and the second to-be-sintered material block are loaded into a sagger together for primary sintering, and using a periphery-center regional mode or an upper-lower-layer distribution mode, the first presintered material is distributed at a periphery or an upper layer, and the second presintered material is distributed at a center or a lower layer.