Recycled electrode active material composition manufactured from waste batteries and method for manufacturing thereof

Patent metadata

Field	Value
Publication number	US-2025038178-A1
Application number	US-202418404297-A
Country	US
Kind code	A1
Filing date	Jan 4, 2024
Priority date	Jul 24, 2023
Publication date	Jan 30, 2025
Grant date	—

Abstract

An embodiment regenerated cathode active material includes a first core region including a cathode active material in a layered crystal structure and a second core region enveloping a portion of the first core region, wherein the regenerated cathode active material has a first mole fraction of particles in the layered crystal structure of 0.96 to 1, has a second mole fraction of particles in a rock salt crystal structure of 0 to 0.02, and has a third mole fraction of particles in a spinel crystal structure of 0 to 0.02 based on the total cathode active material.

First claim

What is claimed is:

1 . A regenerated cathode active material comprising:
a first core region comprising a cathode active material in a layered crystal structure; and a second core region enveloping at least a portion of the first core region, wherein the regenerated cathode active material has a first mole fraction of particles in the layered crystal structure of 0.96 to 1, has a second mole fraction of particles in a rock salt crystal structure of o to 0.02, and has a third mole fraction of particles in a spinel crystal structure of 0 to 0.02 based on the total cathode active material.

2 . The regenerated cathode active material of claim 1 , wherein:
the second core region comprises a first metal element; the first metal element comprises at least one metal element selected from the group consisting of boron (B), zirconium (Zr), titanium (Ti), aluminum (Al), magnesium (Mg), manganese (Mn), cobalt (Co), nickel (Ni), niobium (Nb), tantalum (Ta), and tungsten (W); and a concentration gradient of the first metal element in the cathode active material rises in a stepwise manner based on a first boundary surface between the first core region and the second core region from a center of the first core region and gradually rises from a second boundary surface of the second core region toward an outer direction of the second core region.

3 . The regenerated cathode active material of claim 1 , further comprising a first reinforcement layer enveloping a portion of the second core region, wherein the first reinforcement layer comprises a first metal element, the first metal element comprising at least one metal element selected from the group consisting of boron (B), zirconium (Zr), titanium (Ti), aluminum (Al), magnesium (Mg), manganese (Mn), cobalt (Co), nickel (Ni), niobium (Nb), tantalum (Ta), and tungsten (W).

4 . The regenerated cathode active material of claim 3 , wherein the first reinforcement layer comprises at least one metal element selected from the group consisting of B 2 O 3 , Li 2 O—B 2 O 3 , Li 3 BO 3 , Li 2 B 4 O 7 , Li 2 B 2 O 7 , and Li 2 B 8 O 13 .

5 . The regenerated cathode active material of claim 3 , wherein the first reinforcement layer has a thickness of 1 to 100 nm.

6 . The regenerated cathode active material of claim 3 , wherein:
the regenerated cathode active material further comprises a second reinforcement layer enveloping a portion of the first reinforcement layer; the second reinforcement layer comprises a second metal element; and the second metal element includes at least one metal element selected from the group consisting of boron (B), zirconium (Zr), titanium (Ti), aluminum (Al), magnesium (Mg), manganese (Mn), cobalt (Co), nickel (Ni), niobium (Nb), tantalum (Ta), and tungsten (W).

7 . The regenerated cathode active material of claim 1 , wherein the regenerated cathode active material has a specific surface area of 1.5 m 2 /g or less.

8 . The regenerated cathode active material of claim 1 , wherein the regenerated cathode active material has a particle strength of 80 MPa or more.

9 . The regenerated cathode active material of claim 1 , wherein a content of a residual lithium by-product in the regenerated cathode active material is less than 1.5% by weight based on a total weight of the cathode active material.

10 . A method for preparing a regenerated cathode active material, the method comprising:
mixing a waste battery with a solvent after crushing the waste battery to a first particle size to form a mixture; first precipitating the mixture to form a first precipitate; second precipitating the first precipitate after crushing the first precipitate to a second particle size to form a second precipitate; pressurizing the second precipitate so that the second precipitate has a moisture content of a predetermined % or less; obtaining a black powder comprising a waste cathode active material by drying the pressurized second precipitate; and performing a primary heat treatment after mixing the black powder with a lithium precursor to form a primary heat treatment resulting product.

11 . The method of claim 10 , wherein the waste battery includes at least one selected from the group consisting of lithium nickel cobalt manganese oxide (LiNiCoMnO 2 ; NCM), lithium nickel cobalt aluminum oxide (LiNiCoAlO 2 ; NCA), lithium iron phosphate (LiFePO 4 ; LFP), lithium manganese iron phosphate (LiMnFePO 4 ; LMFP), lithium manganese oxide (LiMn 2 O 4 ; LMO), lithium nickel manganese spinel (LiNi 0.5 Mn 1.5 O 4 ; LNMO), and lithium cobalt oxide (LiCoO 2 ; LCO) series.

12 . The method of claim 10 , wherein the solvent includes at least one selected from the group consisting of water, methanol, ethanol, and acetonitrile.

13 . The method of claim 10 , wherein mixing the waste battery crushed to the first particle size with the solvent is performed at 60 to 100° C. for 2 to 24 hours.

14 . The method of claim 10 , wherein performing the primary heat treatment comprises mixing 1 to 30% by weight of the lithium precursor based on a total weight of the black powder.

15 . The method of claim 10 , wherein performing the primary heat treatment is performed at 200 to 1,000° C. for 3 to 24 hours in an oxygen atmosphere.

16 . The method of claim 10 , wherein performing the primary heat treatment comprises performing the primary heat treatment after mixing the black powder with the lithium precursor and a first metal element precursor, wherein the first metal element precursor includes at least one metal element selected from the group consisting of boron (B), zirconium (Zr), titanium (Ti), aluminum (Al), magnesium (Mg), manganese (Mn), cobalt (Co), nickel (Ni), niobium (Nb), tantalum (Ta), and tungsten (W).

17 . The method of claim 10 , further comprising:
crushing the primary heat treatment resulting product; mixing the crushed primary heat treatment resulting product with a second metal element, wherein the second metal element includes at least one selected from the group consisting of boron (B), zirconium (Zr), titanium (Ti), aluminum (Al), magnesium (Mg), manganese (Mn), cobalt (Co), nickel (Ni), niobium (Nb), tantalum (Ta), and tungsten (W); and performing a secondary heat treatment.

18 . The method of claim 10 , wherein the regenerated cathode active material has a specific surface area of 1.5 m 2 /g or less and wherein the regenerated cathode active material has a particle strength of 80 MPa or more.

19 . The method of claim 10 , wherein a content of a residual lithium by-product in the regenerated cathode active material is less than 1.5% by weight based on a total weight of the regenerated cathode active material.

20 . The method of claim 10 , wherein the regenerated cathode active material comprises:
a first core region comprising a cathode active material in a layered crystal structure; and a second core region enveloping a portion of the first core region, wherein the second core region comprises a first metal element, wherein the first metal element includes at least one selected from the group consisting of boron (B), zirconium (Zr), titanium (Ti), aluminum (Al), magnesium (Mg), manganese (Mn), cobalt (Co), nickel (Ni), niobium (Nb), tantalum (Ta), and tungsten (W), and wherein a concentration gradient of the first metal element in the cathode active material rises in a stepwise manner based on a first boundary surface between the first core region and the second core region from a center of the first core region and gradually rises from a second bou

Assignees

• Hyundai Motor Co Ltd
• Kia Corp

Inventors

• Seo Im Sul
• Min Hong-Seok
• Noh Sung Woo
• Seo Jeong Hyun
• Lim Chung Bum
• Seong Ju Yeong
• Park Je Sik

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• Y02W30/84

  Recycling of batteries or fuel cells · CPC title

• H01M2004/028

  Positive electrodes · CPC title

• H01M10/052

  Li-accumulators · CPC title

• H01M10/54 Primary

  Reclaiming serviceable parts of waste accumulators · CPC title