Nanostructured Zirconium Phosphate for Uniform Cathode Coating
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Solution Overview
Problem
Existing methods for producing zirconium pyrophosphate are time-consuming, costly, and result in materials with broad particle size distribution and poor dispersibility, making them unsuitable for industrial applications in batteries.
Innovation Solution
A flame spray pyrolysis process using specific precursors and solvents produces nanostructured zirconium phosphate with a narrow particle size distribution and high BET surface area, enabling a homogeneous coating on lithium-mixed oxide cathode particles through dry coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flame spray pyrolysis is used to produce zirconium phosphate, then productivity is improved and manufacturing cost is reduced, but particle size distribution becomes broad and dispersibility deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the flame spray pyrolysis parameters including precursor solution composition (zirconium alkoxide to phosphoric acid ratio), solvent type (alcohol vs water), and processing conditions to achieve narrow particle size distribution while maintaining high productivity. This resolves the contradiction by optimizing parameters to simultaneously improve throughput and particle uniformity.
2Ease of manufacture
If flame spray pyrolysis is used to produce zirconium phosphate, then manufacturing cost is reduced, but dispersibility and adhesion deteriorate
Solution Approach 1:
The patent changes the chemical parameters of the precursor solution, specifically using alcohol-based solvents instead of water and controlling the molar ratio of zirconium alkoxide to phosphoric acid. These parameter changes produce particles with improved surface properties that enhance dispersibility in organic solvents while maintaining cost-effective flame spray pyrolysis manufacturing.
3Reliability
If coating thickness is increased to improve protection, then adhesion improves, but ion conductivity deteriorates
Solution Approach 1:
The patent applies local quality by creating a thin, uniform coating layer that provides adequate protective function without excessive thickness. The flame spray pyrolysis process deposits zirconium phosphate in a controlled manner that ensures sufficient adhesion to the cathode material while maintaining thin film morphology that preserves lithium ion conductivity through the coating layer.
4Reliability
If conventional coating methods are used to protect cathode material, then adhesion is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces complex mechanical coating systems with flame spray pyrolysis, a thermal field-based method. This substitution simplifies the manufacturing process by using thermal energy to decompose precursor solutions and deposit coating material directly, eliminating the need for complex mechanical coating equipment and multi-step processing while achieving strong adhesion.
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 process yields zirconium phosphate with improved dispersibility and adhesion, enhancing battery performance by reducing degradation and increasing cycle life.
Implementation Method 1
The invention provides a process for producing zirconium phosphate by means of flame spray pyrolysis
Implementation Method 2
The grey properties results from incomplete combustion of the precursors
Implementation Method 3
Surface coating of cathode active materials has proven to be an extremely important method to address this aging problem by suppressing the direct contact between the active materials surfaces and the liquid electrolyte
Implementation Method 4
zirconium phosphate is in the form of aggregated primary particles
Data Source
AI summary
A process produces zirconium phosphate by flame spray pyrolysis. A solution of at least one zirconium compound, an organic phosphate and a solvent with less than 10% by weight water is subjected to flame spray pyrolysis. Zirconium phosphate obtainable by this process finds application in batteries to encapsulate lithium mixed oxide particles.