Recycling Lithium-Ion Battery Parts Using a Gentle Liquid Method

This patent describes a method for taking apart used lithium-ion batteries by soaking their electrodes in a special liquid to separate valuable materials like active electrode powders from metal collectors, making them easier to reuse.

What it covers

The patent describes a method for recycling lithium-ion battery materials. It starts by taking a "composite electrode," which includes both anode and cathode parts, and mixing it with an "aqueous buffer solution" (Claim 1). This solution helps to "delaminate" (separate) the active electrode material from its metal "current collector." Specifically, the anode active material is separated from its current collector first, then removed (Claim 1). Afterward, a "surfactant" is added to the mixture, and the cathode active material is separated from its current collector (Claim 1). Both the separated active materials and the metal current collectors are then recovered, potentially by sieving or filtration (Claim 8). For example, if you have a used electric vehicle battery, this method would let you get back the graphite from the anode and the lithium cobalt oxide from the cathode, along with the copper and aluminum foils.

What it doesn't cover

• —Does not cover recycling methods that use strong acids or high temperatures to separate battery materials, as it specifies an aqueous buffer solution and mild temperatures (Claim 1, 2, 5).
• —Does not cover methods where anode and cathode materials are delaminated simultaneously, as Claim 1 specifies they are "delaminated sequentially in that order."
• —Does not cover recycling processes that do not involve an aqueous buffer solution to initiate the delamination (Claim 1).
• —Does not cover methods that do not separate the electrode material from the current collector; the core step is "delaminating the electrode material from the current collector" (Claim 1).

The clever bit

The novelty lies in the sequential, gentle delamination process using an aqueous buffer solution, optionally with a surfactant, at relatively mild temperatures. This allows for the separation of active materials from current collectors without destroying them, making recovery easier and potentially more cost-effective than harsher methods.

Why it matters

Lithium-ion batteries power most modern portable electronics and electric vehicles. As more batteries are produced, there's a growing need to efficiently recycle their valuable and sometimes toxic components like lithium, cobalt, and nickel. This patent offers a potentially less energy-intensive and safer way to recover these materials compared to traditional methods that often involve high temperatures or strong, corrosive chemicals. This could reduce environmental impact and improve the supply chain for critical battery materials.

Real-world examples

• 1.Recycling facilities for electric vehicle batteries
• 2.Recycling plants for smartphone and laptop batteries
• 3.Pilot programs for urban mining of electronic waste