1. A system for processing waste lithium-ion batteries, comprising: a deactivation chamber for safely discharging residual energy from incoming waste batteries; a mechanical disassembly unit operatively connected to said deactivation chamber, structured to separate battery components; a solvent-based extraction subsystem fluidly linked to said mechanical disassembly unit, designed to dissolve and separate electrode materials from the separated components; a filtration unit downstream of said extraction subsystem for retaining and isolating valuable metals and materials; and a residual waste management module, operatively connected to said filtration unit, facilitating the safe disposal or repurposing of non-recyclable remnants.

2. The system of claim 1, further comprising: a control and monitoring interface equipped with sensors and feedback mechanisms, tracking the operational efficiency and safety metrics of the processing line.

3. The system of claim 1, wherein: said mechanical disassembly unit incorporates precision robotic arms and cutting tools for enhanced accuracy and safety during the component separation phase.

4. The system of claim 1, further including: an electrolyte neutralization tank connected to said solvent-based extraction subsystem, ensuring the safe treatment and disposal of extracted electrolytes.

5. The system of claim 1, wherein: said filtration unit integrates a multi-layered filter mechanism, each layer optimized for capturing specific metals or materials from the dissolved battery slurry.

6. A method for processing waste lithium-ion batteries, comprising the steps of: introducing the waste batteries into a deactivation chamber for safe discharge of residual energy; mechanically disassembling the deactivated batteries in a dedicated disassembly unit, separating the constituent components; utilizing a solvent-based extraction system to dissolve and isolate electrode materials from the separated components; filtering and retaining valuable metals and materials from the resultant solution using a specialized filtration unit; and managing and disposing of non-recyclable residues through a dedicated waste management module.

7. The method of claim 6, further including: continuously monitoring and adjusting the operational parameters of the processing line using a control and monitoring interface to ensure optimal efficiency and safety.

8. The method of claim 6, wherein: employing precision robotic arms and specialized cutting tools during the mechanical disassembly phase, ensuring accurate and safe separation of battery components.

9. The method of claim 6, involving: neutralizing extracted electrolytes in a dedicated tank post their separation from electrode materials, ensuring their safe treatment and disposal.

10. The method of claim 6, wherein: utilizing a multi-layered filter mechanism within the filtration unit, with each layer being dedicated to capturing specific metals or materials from the dissolved battery solution. WASTE LITHIUM-ION BATTERY PROCESSING SYSTEM Abstract A pioneering system tailored for the meticulous processing of waste lithium-ion batteries is unveiled. At its inception, a deactivation chamber is meticulously engineered to safely dissipate lingering energy from the defunct batteries. Post neutralization, these batteries transition to a mechanical disassembly unit, skillfully segmenting the composite battery constituents. Following this, a solvent-based extraction subsystem seamlessly integrates, purposefully dissolving and partitioning electrode materials from the disassembled ensemble. Ensuring the salvage of precious metals and materials, a subsequent filtration unit diligently retains and sequesters these valuable components. Culminating the processing arc, a residual waste management module interlinks, primed to either safely discard or ingeniously repurpose the non-recyclable vestiges, epitomizing a holistic approach to lithium-ion battery waste management. , Claims:Claims :

1. A system for processing waste lithium-ion batteries, comprising: a deactivation chamber for safely discharging residual energy from incoming waste batteries; a mechanical disassembly unit operatively connected to said deactivation chamber, structured to separate battery components; a solvent-based extraction subsystem fluidly linked to said mechanical disassembly unit, designed to dissolve and separate electrode materials from the separated components; a filtration unit downstream of said extraction subsystem for retaining and isolating valuable metals and materials; and a residual waste management module, operatively connected to said filtration unit, facilitating the safe disposal or repurposing of non-recyclable remnants.

2. The system of claim 1, further comprising: a control and monitoring interface equipped with sensors and feedback mechanisms, tracking the operational efficiency and safety metrics of the processing line.

3. The system of claim 1, wherein: said mechanical disassembly unit incorporates precision robotic arms and cutting tools for enhanced accuracy and safety during the component separation phase.

4. The system of claim 1, further including: an electrolyte neutralization tank connected to said solvent-based extraction subsystem, ensuring the safe treatment and disposal of extracted electrolytes.

5. The system of claim 1, wherein: said filtration unit integrates a multi-layered filter mechanism, each layer optimized for capturing specific metals or materials from the dissolved battery slurry.

6. A method for processing waste lithium-ion batteries, comprising the steps of: introducing the waste batteries into a deactivation chamber for safe discharge of residual energy; mechanically disassembling the deactivated batteries in a dedicated disassembly unit, separating the constituent components; utilizing a solvent-based extraction system to dissolve and isolate electrode materials from the separated components; filtering and retaining valuable metals and materials from the resultant solution using a specialized filtration unit; and managing and disposing of non-recyclable residues through a dedicated waste management module.

7. The method of claim 6, further including: continuously monitoring and adjusting the operational parameters of the processing line using a control and monitoring interface to ensure optimal efficiency and safety.

8. The method of claim 6, wherein: employing precision robotic arms and specialized cutting tools during the mechanical disassembly phase, ensuring accurate and safe separation of battery components.

9. The method of claim 6, involving: neutralizing extracted electrolytes in a dedicated tank post their separation from electrode materials, ensuring their safe treatment and disposal.

10. The method of claim 6, wherein: utilizing a multi-layered filter mechanism within the filtration unit, with each layer being dedicated to capturing specific metals or materials from the dissolved battery solution.

Description:WASTE LITHIUM-ION BATTERY PROCESSING SYSTEM
Field of the Invention
[0001] The present invention falls within the ambit of environmental engineering and waste management, with a specific emphasis on the recycling and processing of electronic waste. More precisely, the invention relates to a system devised for the efficient processing of discarded lithium-ion batteries. Recognizing the escalating global demand for lithium-ion batteries in various applications, from portable electronics to electric vehicles, this system addresses the mounting challenge of handling their end-of-life phase. The presented system incorporates methods and apparatuses to safely dismantle, segregate, and extract valuable components and materials from spent lithium-ion batteries. In doing so, the invention not only mitigates potential environmental hazards but also offers a sustainable avenue for resource recovery and reintroduction of these materials into the manufacturing cycle.
Background
[0002] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] The increasing use of lithium-ion batteries in various applications, from consumer electronics to electric vehicles, has led to concerns about the management of waste batteries at the end of their lifecycle. Improper disposal of these batteries can lead to environmental pollution and the loss of valuable resources. To address these challenges, the development of waste lithium-ion battery processing systems has become crucial. These systems aim to safely and efficiently recover valuable materials while minimizing environmental impact.
[0004] Lithium-ion batteries comprise various components, including electrodes, electrolytes, separators, and casing materials. They can contain valuable metals like lithium, cobalt, nickel, and copper, as well as hazardous substances. The challenge lies in the complex chemistry of these batteries and the need to extract valuable materials without causing harm to the environment.
[0005] A waste lithium-ion battery processing system typically consists of several key components:
[0006] The initial step involves the careful disassembly of batteries to separate their components, including electrodes, electrolytes, and casing materials.
[0007] The recovery of valuable materials from electrodes is a critical step. Various methods, such as hydrometallurgical and pyrometallurgical processes, can be used to extract metals like lithium, cobalt, and nickel.
[0008] The electrolyte, which often contains solvents and salts, needs proper treatment to avoid environmental contamination. Techniques such as solvent extraction and precipitation can be employed to recover and purify electrolyte components.
[0009] Implementing safety measures is vital to prevent the release of hazardous substances during the processing. Proper ventilation, waste disposal, and the use of personal protective equipment are essential.
[00010] Numerous studies and industrial initiatives have contributed to the development of waste lithium-ion battery processing systems:
[00011] Umicore, a materials technology company, has established a recycling process for lithium-ion batteries. Their method involves disassembling batteries, recovering valuable metals through smelting, and purifying these metals for reuse.
[00012] Li-Cycle, a battery recycling company, employs a hydrometallurgical process to recycle lithium-ion batteries. They use a combination of mechanical and chemical processes to recover cathode materials like lithium, cobalt, and nickel.
[00013] Recycling Technologies, a UK-based company, has developed a solution called "Cathode De-Lamination," which involves using heat to separate the components of lithium-ion batteries. This approach aims to recover clean, undamaged materials for reuse.
[00014] Researchers at Stanford University have explored approaches to lithium-ion battery recycling. One study focused on using a specialized cryogenic technique to selectively freeze and fracture electrode materials, facilitating their separation and recovery.
[00015] The European Union has launched initiatives like the Horizon 2020 program to support research in battery recycling. Projects like "RECYCALYSE" aim to develop methods for recycling lithium-ion batteries and promoting a circular economy.
[00016] In conclusion, waste lithium-ion battery processing systems are crucial for managing the growing volume of discarded batteries while recovering valuable materials in an environmentally responsible manner. Efforts by companies, research institutions, and governments are driving advancements in recycling technologies, aiming to reduce the environmental impact of battery waste and promote sustainable resource utilization.
[00017] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
Summary
[00018] Various objects, features, and advantages of the disclosed subject matter can be more fully appreciated with reference to the following detailed description of the disclosed subject matter when considered in connection with the following drawings, in which like reference numerals identify like elements.
[00019] The present invention falls within the ambit of environmental engineering and waste management, with a specific emphasis on the recycling and processing of electronic waste. More precisely, the invention relates to a system devised for the efficient processing of discarded lithium-ion batteries. Recognizing the escalating global demand for lithium-ion batteries in various applications, from portable electronics to electric vehicles, this system addresses the mounting challenge of handling their end-of-life phase. The presented system incorporates methods and apparatuses to safely dismantle, segregate, and extract valuable components and materials from spent lithium-ion batteries. In doing so, the invention not only mitigates potential environmental hazards but also offers a sustainable avenue for resource recovery and reintroduction of these materials into the manufacturing cycle.
[00020] Described herein a waste lithium-ion battery processing system offers an advanced and comprehensive solution for the environmentally sound management of used batteries. Through a series of sophisticated steps, this system effectively disassembles and separates components, facilitating valuable material recovery while ensuring safe waste management.
[00021] At its core, the system features a deactivation chamber designed to safely discharge any residual energy remaining in the incoming waste batteries. This initial step minimizes potential hazards during subsequent processing. Connected to this chamber is a mechanical disassembly unit, which employs precision robotic arms and cutting tools to separate battery components accurately and safely.
[00022] Following the mechanical disassembly, a solvent-based extraction subsystem comes into play. This subsystem fluidly connects to the disassembly unit and employs solvents to dissolve and separate electrode materials from the components. This dissolution process results in the creation of a dissolved battery slurry, from which valuable materials can be extracted.
[00023] To capture these valuable materials, a filtration unit is positioned downstream from the extraction subsystem. This unit employs a multi-layered filter mechanism, with each layer optimized to capture specific metals or materials from the dissolved battery slurry. This strategic approach enhances material recovery efficiency.
[00024] An integral aspect of the system is the residual waste management module, which ensures the proper treatment and disposal of non-recyclable remnants. This module emphasizes environmental responsibility by either safely disposing of waste or identifying potential repurposing opportunities.
[00025] To ensure operational efficiency and safety, the system incorporates a control and monitoring interface equipped with sensors and feedback mechanisms. This interface continually tracks and evaluates operational parameters, safety metrics, and process efficiency along the entire processing line.
[00026] The system's commitment to safety and responsible waste management is further demonstrated by the electrolyte neutralization tank. This tank is connected to the solvent-based extraction subsystem and plays a crucial role in safely treating and disposing of extracted electrolytes, minimizing environmental impact.
[00027] In summary, the waste lithium-ion battery processing system represents holistic approach to managing used batteries. By combining safe energy discharge, precise mechanical disassembly, solvent-based extraction, selective filtration, and responsible waste management, this integrated system maximizes material recovery while minimizing environmental and safety concerns. Its robust operational monitoring and commitment to environmentally sound practices make it a promising contender in the realm of waste battery processing.
[00028] The waste lithium-ion battery processing method described here presents a comprehensive and sophisticated approach to the responsible management of discarded batteries. This method systematically guides the transformation of waste batteries into valuable materials, while prioritizing safety, efficiency, and environmental sustainability.
[00029] The method commences with the introduction of waste batteries into a deactivation chamber, a crucial step that ensures the safe discharge of any remaining energy from the batteries. This initial precautionary measure minimizes risks and hazards as the processing proceeds.
[00030] Subsequently, the deactivated batteries undergo mechanical disassembly within a dedicated unit. This process is carried out with the aid of precision robotic arms and specialized cutting tools, ensuring accurate and safe separation of battery components. This precise disassembly paves the way for the effective recovery of valuable materials.
[00031] The core of the method involves a solvent-based extraction system that dissolves and isolates electrode materials from the separated components. Through this step, electrode materials are transformed into a dissolved solution, creating the foundation for material recovery.
[00032] The dissolved solution is then subjected to a specialized filtration unit. This unit employs a multi-layered filter mechanism, where each layer is optimized to capture specific metals or materials from the dissolved battery solution. This strategic approach enhances the efficiency of material recovery.
[00033] Integral to the method is the management of non-recyclable residues. A dedicated waste management module addresses these residues, ensuring their responsible disposal or identifying potential opportunities for repurposing.
[00034] The method's commitment to operational efficiency and safety is further underscored by the integration of a control and monitoring interface. This interface continuously monitors and adjusts the operational parameters of the processing line, guaranteeing optimal efficiency and safety throughout the entire process.
[00035] For environmentally sound practices, the method includes a step to neutralize extracted electrolytes. These electrolytes are safely treated and disposed of in a dedicated tank after their separation from the electrode materials.
[00036] In summary, the waste lithium-ion battery processing method presents a robust and forward-looking approach to transforming discarded batteries into valuable resources. By combining safe discharge, precise mechanical disassembly, solvent-based extraction, selective filtration, and responsible waste management, this method maximizes material recovery while minimizing environmental impact and safety concerns. Its systematic procedures and commitment to sustainability position it as a promising contender in the realm of waste battery processing.
Brief Description of the Drawings
[00037] The features and advantages of the present disclosure would be more clearly understood from the following description taken in conjunction with the accompanying drawings in which:
[00038] FIG. 1 pictorially portrays an architectural paradigm of a system for processing waste lithium-ion batteries, according to some embodiments of the present disclosure.
[00039] FIG. 2 figuratively illustrates an exemplary schematic flow diagram of a method for processing waste lithium-ion batteries, according to some embodiments of the present disclosure.
Detailed Description
[00040] The following is a detailed description of exemplary embodiments to illustrate the principles of the invention. The embodiments are provided to illustrate aspects of the invention, but the invention is not limited to any embodiment. The scope of the invention encompasses numerous alternatives, modifications and equivalent; it is limited only by the claims.
[00041] In view of the many possible embodiments to which the principles of the present discussion may be applied, it should be recognized that the embodiments described herein with respect to the drawing figures are meant to be illustrative only and should not be taken as limiting the scope of the claims. Therefore, the techniques as described herein contemplate all such embodiments as may come within the scope of the following claims and equivalents thereof.
[00042] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different instances in the description and the figures may indicate similar or identical items.
[00043] Pursuant to the "Detailed Description" section herein, whenever an element is explicitly associated with a specific numeral for the first time, such association shall be deemed consistent and applicable throughout the entirety of the "Detailed Description" section, unless otherwise expressly stated or contradicted by the context.
[00044] The present invention falls within the ambit of environmental engineering and waste management, with a specific emphasis on the recycling and processing of electronic waste. More precisely, the invention relates to a system devised for the efficient processing of discarded lithium-ion batteries. Recognizing the escalating global demand for lithium-ion batteries in various applications, from portable electronics to electric vehicles, this system addresses the mounting challenge of handling their end-of-life phase. The presented system incorporates methods and apparatuses to safely dismantle, segregate, and extract valuable components and materials from spent lithium-ion batteries. In doing so, the invention not only mitigates potential environmental hazards but also offers a sustainable avenue for resource recovery and reintroduction of these materials into the manufacturing cycle.
[00045] Pursuant to the "Detailed Description" section herein, whenever an element is explicitly associated with a specific numeral for the first time, such association shall be deemed consistent and applicable throughout the entirety of the "Detailed Description" section, unless otherwise expressly stated or contradicted by the context.
[00046] As the world transitions towards cleaner and more sustainable energy sources, the proliferation of lithium-ion batteries has become integral to various industries, from portable electronics to electric vehicles. However, the growing usage of these batteries has raised concerns about the environmental impact posed by their disposal. In response to this challenge, a sophisticated system 100 for processing waste lithium-ion batteries has been developed, aiming to safely and efficiently manage the disposal of these batteries while also recovering valuable materials for reuse.
[00047] The escalating demand for lithium-ion batteries, coupled with their finite lifespan, has led to the accumulation of waste batteries. Improper disposal of these batteries poses environmental and health hazards due to the presence of toxic and flammable components. The system 100 described herein presents an approach to managing waste lithium-ion batteries. It encompasses a series of interconnected units and subsystems, each designed to address specific stages of the battery processing cycle. By integrating mechanisms for discharging residual energy, mechanical disassembly, solvent-based extraction, filtration, and residual waste management, this system offers a comprehensive solution for handling waste batteries. According to a pictorial portrayal in FIG. 1, illustrating an architectural setup of the system 100 comprises a deactivation chamber 102, mechanical disassembly unit 104, solvent-based extraction subsystem 106, filtration unit 108, and residual waste management module 110.
[00048] The system 100 initiates with a deactivation chamber, strategically positioned to safely discharge any residual energy stored within the incoming waste batteries. Battery cells contain stored electrical energy that can pose risks if not properly neutralized prior to disassembly. The deactivation chamber provides a controlled environment where the residual energy is safely dissipated, ensuring the subsequent processing steps are carried out under safe conditions.
[00049] Connected to the deactivation chamber is the mechanical disassembly unit, which plays a pivotal role in separating the various components of the waste batteries. This unit employs precision robotic arms and cutting tools to disassemble the batteries accurately and safely. The precision of the robotic arms minimizes the potential for accidents and enhances the efficiency of the disassembly process. The mechanical

disassembly unit systematically separates the battery into its constituent parts, including the casing, electrodes, and other components.
[00050] Following mechanical disassembly, the separated components proceed to the solvent-based extraction subsystem. This subsystem is fluidly linked to the mechanical disassembly unit and is designed to dissolve and separate electrode materials from the battery components. Solvent-based extraction offers an efficient method for recovering valuable materials, such as lithium, cobalt, and nickel, present in the electrodes. The solvent dissolves the electrode materials while leaving other components intact, facilitating material recovery.
[00051] Downstream of the extraction subsystem lies the filtration unit, a critical component responsible for retaining and isolating valuable metals and materials recovered from the dissolved battery slurry. This unit employs a multi-layered filter mechanism, with each layer optimized for capturing specific metals or materials. For instance, one layer might be tailored to capture cobalt, another for lithium, and so forth. This sophisticated filtration process enhances the precision and efficiency of material recovery, ensuring that valuable resources are not lost.
[00052] In an embodiment, the recovered metals and materials are sent for further processing or repurposing, contributing to the circular economy by reducing the need for new raw materials. However, not all components of the waste batteries can be recycled. The residual waste management module is designed to manage the non-recyclable remnants in a responsible manner. This module ensures that any waste materials that cannot be reused or repurposed are safely disposed of, following appropriate regulations and standards to minimize environmental impact.
[00053] In an embodiment, the system 100 includes a control and monitoring interface equipped with sensors and feedback mechanisms. This interface continuously tracks the operational efficiency and safety metrics of the processing line. Real-time data from sensors inform operators about critical parameters such as temperature, pressure, and chemical concentrations. By providing this information, the interface allows for prompt adjustments and interventions to optimize performance and ensure safety.
[00054] An electrolyte neutralization tank is integrated into the system, connected to the solvent-based extraction subsystem. This tank serves the crucial purpose of treating and neutralizing the extracted electrolytes. Lithium-ion batteries contain electrolytes that are flammable and can pose environmental risks if not properly managed. The electrolyte neutralization tank ensures the safe treatment and disposal of these extracted electrolytes, further enhancing the system's environmental compatibility.
[00055] Referring to one or more preceding embodiments, the described system 100 for processing waste lithium-ion batteries embodies a holistic and sustainable approach to addressing the challenges posed by the increasing accumulation of battery waste. By incorporating units and subsystems such as the deactivation chamber, mechanical disassembly unit, solvent-based extraction subsystem, filtration unit, and residual waste management module, this system efficiently recovers valuable materials while ensuring safe disposal of non-recyclable remnants. The integration of advanced technologies such as precision robotic arms, multi-layered filtration, and real-time monitoring interfaces underscores the sophistication and efficacy of the system. Ultimately, this approach not only minimizes the environmental impact of waste lithium-ion batteries but also contributes to the conservation of valuable resources and the promotion of a greener future.
[00056] In a world propelled by technological advancements and an increasing demand for portable power sources, lithium-ion batteries have emerged as a cornerstone of modern energy storage. From powering smartphones and laptops to driving electric vehicles, these batteries have revolutionized the way we live and work. However, the pervasive use of lithium-ion batteries has inevitably led to a significant challenge, the management of waste batteries. To address this concern, a method 200 for processing waste lithium-ion batteries has been meticulously developed, offering an intricate and environmentally conscious approach to tackling the escalating issue of battery waste.
[00057] As technology evolves at an unprecedented pace, so does the need for sustainable solutions to manage the waste generated by our modern way of life. The disposal of waste lithium-ion batteries poses unique challenges due to the potential risks associated with their components, such as toxic materials and residual energy. The method 200 outlined here presents a comprehensive approach to processing waste lithium-ion batteries, ensuring both the safe disposal of hazardous materials and the recovery of valuable resources for potential reuse. By integrating multiple stages and specialized units, this method exemplifies a holistic and sophisticated response to the challenges of battery waste.
[00058] Figuratively depicted in FIG. 2, representing a flow diagram of the method 200 for processing waste lithium-ion batteries, comprising the steps of (at step 202) introducing the waste batteries into a deactivation chamber for safe discharge of residual energy, (at step 204) mechanically disassembling the deactivated batteries in a dedicated disassembly unit, separating the constituent components(at step 206) utilizing a solvent-based extraction system to dissolve and isolate electrode materials from the separated components(at step 208) filtering and retaining valuable metals and materials from the resultant solution using a specialized filtration unit(at step 210) and managing and disposing of non-recyclable residues through a dedicated waste management module.
[00059] In yet another embodiment, the method 200 commences with the introduction of waste batteries into a specially designed deactivation chamber. This chamber serves as a controlled environment where residual energy stored within the batteries is safely discharged. Prior to disassembly, discharging residual energy is crucial to prevent potential hazards arising from accidental short circuits during the processing stages. By neutralizing the energy in this early phase, the subsequent steps are carried out in a safe and controlled manner, minimizing risks to both personnel and the environment.
[00060] Once residual energy is discharged, the deactivated batteries move to a dedicated mechanical disassembly unit. This unit is at the heart of the process, responsible for the accurate and safe separation of the various components of the waste batteries. Precision robotic arms equipped with specialized cutting tools ensure the systematic separation of the battery into its constituent parts, including the casing, electrodes, electrolytes, and other components. The use of precision robotics minimizes the potential for human error and enhances the efficiency of the disassembly process.
[00061] Following mechanical disassembly, the process moves to the utilization of a solvent-based extraction system. This subsystem is designed to dissolve and isolate electrode materials from the separated battery components. The use of solvents provides an efficient means of extracting valuable materials such as lithium, cobalt, and nickel from the electrodes. This approach allows for the recovery of these resources for potential reuse in future battery manufacturing or other applications, contributing to the circular economy and reducing the need for new raw materials.
[00062] The solution containing dissolved electrode materials progresses to a specialized filtration unit. This unit employs a multi-layered filter mechanism, each layer optimized to capture specific metals or materials from the dissolved battery solution. For instance, one layer may target the recovery of cobalt, while another focuses on lithium. The intricate design of the filtration unit ensures that valuable materials are effectively captured and retained, further enhancing the sustainability and resource efficiency of the method.
[00063] As the filtration process concludes, the method addresses the non-recyclable residues that remain. These remnants, which may include materials unsuitable for reuse or repurposing, are managed through a dedicated waste management module. This module ensures that these residues are safely disposed of or repurposed in an environmentally responsible manner, adhering to stringent regulations and minimizing the potential environmental impact.
[00064] To ensure the optimal efficiency and safety of the processing line, the method incorporates a control and monitoring interface equipped with sensors and feedback mechanisms. This interface continuously tracks various operational parameters, such as temperature, pressure, and chemical concentrations. Real-time data from these sensors enable operators to make informed decisions, promptly addressing any deviations from the desired operational conditions.
[00065] In alignment with its environmentally conscious approach, the method includes an electrolyte neutralization tank. This tank is connected to the solvent-based extraction subsystem and serves to neutralize the extracted electrolytes. Electrolytes, being flammable and potentially hazardous, require careful management. The electrolyte neutralization tank ensures the safe treatment and disposal of these extracted electrolytes, mitigating potential risks and enhancing the overall safety of the process.
[00066] Referring to one or more preceding embodiments, the method 200 for processing waste lithium-ion batteries represents a remarkable amalgamation of environmental responsibility and resource recovery. By sequentially introducing waste batteries into a deactivation chamber, mechanically disassembling them with precision robotics, utilizing a solvent-based extraction system, filtering and retaining valuable materials, and managing non-recyclable residues, this method provides a comprehensive solution to the challenges posed by battery waste. The integration of advanced technologies, such as precision robotics, multi-layered filtration, and real-time monitoring, underscores the sophistication and efficacy of the method. Ultimately, this approach not only mitigates the environmental impact of waste lithium-ion batteries but also contributes to the conservation of valuable resources and the promotion of a more sustainable future.
[00067] Further, while operations are depicted in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Likewise, while several specific implementation details are contained in the above discussions, these should not be construed as limitations on the scope of the subject matter described herein, but rather as descriptions of features that may be specific to particular embodiments. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
[00068] The term “memory,” as used herein relates to a volatile or persistent medium, such as a magnetic disk, or optical disk, in which a computer can store data or software for any duration. Optionally, the memory is non-volatile mass storage such as physical storage media. Furthermore, a single memory may encompass and in a scenario wherein computing system is distributed, the processing, memory and/or storage capability may be distributed as well.
[00069] Throughout the present disclosure, the term ‘server’ relates to a structure and/or module that include programmable and/or non-programmable components configured to store, process and/or share information. Optionally, the server includes any arrangement of physical or virtual computational entities capable of enhancing information to perform various computational tasks.
[00070] Throughout the present disclosure, the term “network” relates to an arrangement of interconnected programmable and/or non-programmable components that are configured to facilitate data communication between one or more electronic devices and/or databases, whether available or known at the time of filing or as later developed. Furthermore, the network may include, but is not limited to, one or more peer-to-peer network, a hybrid peer-to-peer network, local area networks (LANs), radio access networks (RANs), metropolitan area networks (MANS), wide area networks (WANs), all or a portion of a public network such as the global computer network known as the Internet, a private network, a cellular network and any other communication system or systems at one or more locations.
[00071] Throughout the present disclosure, the term “process”* relates to any collection or set of instructions executable by a computer or other digital system so as to configure the computer or the digital system to perform a task that is the intent of the process.
[00072] Throughout the present disclosure, the term ‘Artificial intelligence (AI)’ as used herein relates to any mechanism or computationally intelligent system that combines knowledge, techniques, and methodologies for controlling a bot or other element within a computing environment. Furthermore, the artificial intelligence (AI) is configured to apply knowledge and that can adapt it-self and learn to do better in changing environments. Additionally, employing any computationally intelligent technique, the artificial intelligence (AI) is operable to adapt to unknown or changing environment for better performance. The artificial intelligence (AI) includes fuzzy logic engines, decision-making engines, preset targeting accuracy levels, and/or programmatically intelligent software.

Claims
I/We Claim:
1. A system for processing waste lithium-ion batteries, comprising:
a deactivation chamber for safely discharging residual energy from incoming waste batteries;
a mechanical disassembly unit operatively connected to said deactivation chamber, structured to separate battery components;
a solvent-based extraction subsystem fluidly linked to said mechanical disassembly unit, designed to dissolve and separate electrode materials from the separated components;
a filtration unit downstream of said extraction subsystem for retaining and isolating valuable metals and materials; and
a residual waste management module, operatively connected to said filtration unit, facilitating the safe disposal or repurposing of non-recyclable remnants.
2. The system of claim 1, further comprising:
a control and monitoring interface equipped with sensors and feedback mechanisms, tracking the operational efficiency and safety metrics of the processing line.
3. The system of claim 1, wherein:
said mechanical disassembly unit incorporates precision robotic arms and cutting tools for enhanced accuracy and safety during the component separation phase.
4. The system of claim 1, further including:
an electrolyte neutralization tank connected to said solvent-based extraction subsystem, ensuring the safe treatment and disposal of extracted electrolytes.
5. The system of claim 1, wherein:
said filtration unit integrates a multi-layered filter mechanism, each layer optimized for capturing specific metals or materials from the dissolved battery slurry.
6. A method for processing waste lithium-ion batteries, comprising the steps of:
introducing the waste batteries into a deactivation chamber for safe discharge of residual energy;
mechanically disassembling the deactivated batteries in a dedicated disassembly unit, separating the constituent components;
utilizing a solvent-based extraction system to dissolve and isolate electrode materials from the separated components;
filtering and retaining valuable metals and materials from the resultant solution using a specialized filtration unit; and
managing and disposing of non-recyclable residues through a dedicated waste management module.
7. The method of claim 6, further including:
continuously monitoring and adjusting the operational parameters of the processing line using a control and monitoring interface to ensure optimal efficiency and safety.
8. The method of claim 6, wherein:
employing precision robotic arms and specialized cutting tools during the mechanical disassembly phase, ensuring accurate and safe separation of battery components.
9. The method of claim 6, involving:
neutralizing extracted electrolytes in a dedicated tank post their separation from electrode materials, ensuring their safe treatment and disposal.
10. The method of claim 6, wherein:
utilizing a multi-layered filter mechanism within the filtration unit, with each layer being dedicated to capturing specific metals or materials from the dissolved battery solution.

WASTE LITHIUM-ION BATTERY PROCESSING SYSTEM
Abstract
A pioneering system tailored for the meticulous processing of waste lithium-ion batteries is unveiled. At its inception, a deactivation chamber is meticulously engineered to safely dissipate lingering energy from the defunct batteries. Post neutralization, these batteries transition to a mechanical disassembly unit, skillfully segmenting the composite battery constituents. Following this, a solvent-based extraction subsystem seamlessly integrates, purposefully dissolving and partitioning electrode materials from the disassembled ensemble. Ensuring the salvage of precious metals and materials, a subsequent filtration unit diligently retains and sequesters these valuable components. Culminating the processing arc, a residual waste management module interlinks, primed to either safely discard or ingeniously repurpose the non-recyclable vestiges, epitomizing a holistic approach to lithium-ion battery waste management. , Claims:Claims
I/We Claim:
1. A system for processing waste lithium-ion batteries, comprising:
a deactivation chamber for safely discharging residual energy from incoming waste batteries;
a mechanical disassembly unit operatively connected to said deactivation chamber, structured to separate battery components;
a solvent-based extraction subsystem fluidly linked to said mechanical disassembly unit, designed to dissolve and separate electrode materials from the separated components;
a filtration unit downstream of said extraction subsystem for retaining and isolating valuable metals and materials; and
a residual waste management module, operatively connected to said filtration unit, facilitating the safe disposal or repurposing of non-recyclable remnants.
2. The system of claim 1, further comprising:
a control and monitoring interface equipped with sensors and feedback mechanisms, tracking the operational efficiency and safety metrics of the processing line.
3. The system of claim 1, wherein:
said mechanical disassembly unit incorporates precision robotic arms and cutting tools for enhanced accuracy and safety during the component separation phase.
4. The system of claim 1, further including:
an electrolyte neutralization tank connected to said solvent-based extraction subsystem, ensuring the safe treatment and disposal of extracted electrolytes.
5. The system of claim 1, wherein:
said filtration unit integrates a multi-layered filter mechanism, each layer optimized for capturing specific metals or materials from the dissolved battery slurry.
6. A method for processing waste lithium-ion batteries, comprising the steps of:
introducing the waste batteries into a deactivation chamber for safe discharge of residual energy;
mechanically disassembling the deactivated batteries in a dedicated disassembly unit, separating the constituent components;
utilizing a solvent-based extraction system to dissolve and isolate electrode materials from the separated components;
filtering and retaining valuable metals and materials from the resultant solution using a specialized filtration unit; and
managing and disposing of non-recyclable residues through a dedicated waste management module.
7. The method of claim 6, further including:
continuously monitoring and adjusting the operational parameters of the processing line using a control and monitoring interface to ensure optimal efficiency and safety.
8. The method of claim 6, wherein:
employing precision robotic arms and specialized cutting tools during the mechanical disassembly phase, ensuring accurate and safe separation of battery components.
9. The method of claim 6, involving:
neutralizing extracted electrolytes in a dedicated tank post their separation from electrode materials, ensuring their safe treatment and disposal.
10. The method of claim 6, wherein:
utilizing a multi-layered filter mechanism within the filtration unit, with each layer being dedicated to capturing specific metals or materials from the dissolved battery solution.