Tutton's Salt Cathode Precursors from Recycled Metals
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Solution Overview
Problem
The high demand and insecure supply chains of nickel and cobalt, along with their scarcity and cost, pose challenges for the production of high-energy density lithium-ion battery cathodes like LiNiMnCoOx, necessitating a more sustainable and secure sourcing method.
Innovation Solution
A method is developed to form cathode materials using Tutton's salt, which is sourced from recycled metals, allowing for the preparation of a cathode precursor material through a hydrothermal synthesis process, enabling tunable metal ratios and reducing reliance on non-domestic sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional sulfate salts are used to produce cathode materials, then high energy density (300 Wh/kg) is achieved, but supply chain insecurity and high cost due to nickel and cobalt scarcity occur
Solution Approach 1:
The patent changes the chemical form of metal salts from conventional sulfates to Tutton's salts ((NH4)2M(SO4)2·6H2O), which have different solubility and crystallization properties. This parameter change enables the use of recycled metal sources while maintaining the required energy density of 300 Wh/kg for NMC cathodes
Solution Approach 2:
The invention recovers metals from recycled sources and transforms them into Tutton's salt form, which can then be used to produce cathode materials. This circular approach secures the supply chain by utilizing recovered metals instead of relying on primary mining of scarce nickel and cobalt
2Quantity of substance
If nickel and cobalt are sourced from non-domestic regions, then high energy density cathodes are produced, but cost increases and supply chain becomes insecure
Solution Approach 1:
The patent implements a recovery process that transforms waste or recycled metal sources into valuable Tutton's salts, which serve as precursors for cathode materials. This eliminates dependence on expensive imported nickel and cobalt, reducing manufacturing costs while maintaining metal availability
Solution Approach 2:
The invention uses Tutton's salts as a temporary, easily processable intermediate form that can be synthesized from cheap recycled metal sources. These salts serve as a disposable precursor that is converted into the final cathode material, avoiding the need to handle and store expensive pure metal salts
3Reliability
If Tutton's salt is used as precursor, then supply chain security and cost are improved, but additional processing steps (chelating agent addition and heating) are required
Solution Approach 1:
The patent introduces chelating agents (oxalic acid, citric acid) as intermediaries that facilitate the conversion of Tutton's salts into cathode precursor materials. These chelating agents mediate the chemical transformation by forming soluble complexes that enable controlled precipitation of the desired cathode material phase
Solution Approach 2:
The invention uses controlled heating to change the thermal parameters of the Tutton's salt/chelating agent solution, triggering the decomposition and formation of the cathode precursor material. This thermal parameter change drives the phase transformation while maintaining process simplicity
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 provides a sustainable and cost-effective solution by utilizing recycled metals to produce high-performance cathode materials, alleviating supply chain insecurities and enhancing the domestic supply of lithium-ion battery cathodes.
Implementation Method 1
combining a Tutton's salt exhibiting the chemical formula (NH4)2M(SO4)2·6H2O, wherein M comprises one or more metals and water to form a Tutton's salt solution
Implementation Method 2
adding a chelating agent to the Tutton's salt solution to form a Tutton's salt/chelating agent solution
Implementation Method 3
heating the Tutton's salt/chelating agent solution to form a cathode precursor material comprising a mixed metal composition of the Tutton's salt
Implementation Method 4
heating the Tutton's salt/chelating agent solution to form a cathode precursor material
Data Source
AI summary
A method of preparing a cathode precursor material comprising combining a Tutton's salt exhibiting the chemical formula (NH4)2M(SO4)2·6H2O, wherein M comprises one or more metals, and water to form a Tutton's salt solution, adding a chelating agent to the Tutton's salt solution to form a Tutton's salt/chelating agent solution, and heating the Tutton's salt/chelating agent solution to form a cathode precursor material comprising a mixed metal composition of the Tutton's salt. Additional methods are disclosed.