US 11,955,613 B2
Charge material for recycled lithium-ion batteries
Yan Wang, Acton, MA (US); Eric Gratz, Worcester, MA (US); Qina Sa, Worcester, MA (US); Zhangfeng Zheng, Worcester, MA (US); Joseph Heelan, Woodstock, CT (US); and Kee-Chan Kim, Worcester, MA (US)
Assigned to Worcester Polytechnic Institute, Worcester, MA (US)
Filed by Worcester Polytechnic Institute, Worcester, MA (US)
Filed on Aug. 26, 2021, as Appl. No. 17/412,742.
Application 17/412,742 is a continuation in part of application No. 16/164,952, filed on Oct. 19, 2018, granted, now 11,127,992.
Application 16/164,952 is a continuation in part of application No. 15/358,862, filed on Nov. 22, 2016, granted, now 10,522,884, issued on Dec. 31, 2019.
Application 15/358,862 is a continuation in part of application No. 13/855,994, filed on Apr. 3, 2013, granted, now 9,834,827, issued on Dec. 5, 2017.
Claims priority of provisional application 62/259,161, filed on Nov. 24, 2015.
Claims priority of provisional application 61/620,051, filed on Apr. 4, 2012.
Prior Publication US 2021/0391606 A1, Dec. 16, 2021
Int. Cl. H01M 10/54 (2006.01); C22B 1/24 (2006.01); C22B 3/00 (2006.01); C22B 7/00 (2006.01); C22B 26/22 (2006.01)
CPC H01M 10/54 (2013.01) [C22B 1/24 (2013.01); C22B 7/007 (2013.01); C22B 23/0423 (2013.01); C22B 23/043 (2013.01); C22B 23/0438 (2013.01); C22B 26/22 (2013.01)] 18 Claims
OG exemplary drawing
 
1. In a recycling stream of exhausted secondary batteries, a method of recycling charge materials from the batteries for use in production of recycled batteries, comprising:
receiving a granular mass from a recycling stream based on dismantled batteries, the recycling stream including a plurality of charge materials defined by a battery chemistry of the dismantled batteries, each charge material of the plurality of charge materials defined by a metal and having an oxidation state, the battery chemistry defining a ratio of the charge materials for inclusion in a recycled battery;
adding a leach acid to the granular mass for reducing a pH of the leach solution to dissolve the charge materials in the leach solution, the leach acid selected based on an oxidation state of metal ions defining the dissolved charge materials in the leach solution;
performing a ratio adjustment of the charge materials for achieving a predetermined molar ratio of the charge materials in the leach solution; and
adding a base to the leach solution for raising the pH to precipitate a granular form of compounds of the charge materials, the granular form defining a charge material precursor responsive to sintering to form the recycled batteries.