Multicomponent nanoparticle materials and process and apparatus therefor

Abstract

Multicomponent nanoparticles materials and apparatuses and processes therefor are disclosed. In one aspect of the disclosure, separate particles generated from solution or suspension or by flame synthesis or flame spray pyrolysis, and the resultant particles are mixed in chamber prior to collection or deposition. In another aspect of the disclosure, nanoparticles are synthesized in stagnation or Bunsen flames and allowed to deposit by theirnophoresis on a moving substrate. These techniques are scalable allowing mass production of multicomponent nanoparticles materials and films. The foregoing techniques can be used to prepare composites and component devices comprising one ore more lithium based particles intimately mixed with carbon particles.

1 - 15 . (canceled) 
     
     
         16 . An apparatus for combining distinct aerosols, the apparatus comprising a first burner or atomizer for forming a first aerosol; a second burner or atomizer forming a second aerosol; a chamber in fluid communication with the first and second burner or atomizer for receiving and mixing the first and second aerosols; and an exit port connected to the chamber for allowing the aerosols to escape the chamber, wherein the first burner or atomizer is capable of either: (a) forming an aerosol that is compositionally distinct from the aerosol formed from the second burner or atomizer or (b) forming an aerosol that has an average size that is significantly different from the aerosol formed from the second burner or atomizer. 
     
     
         17 . The apparatus according to  claim 16 , wherein the apparatus comprises a first burner for forming the first aerosol and a second atomizer forming the second aerosol. 
     
     
         18 . The apparatus according to  claim 16 , wherein the first or second burner or atomizer has a nozzle or aperture in the form of a slot. 
     
     
         19 . The apparatus according to  claim 16 , wherein the chamber or exit port is configured in the form of a slot. 
     
     
         20 . The apparatus according to  claim 16 , wherein the first and second burner or atomizer and the chamber and exit port are configured in the form of a slot. 
     
     
         21 . A process of forming lithium active compound particles, the process comprising: forming an aerosol in a chamber from an aqueous medium of a lithium active compound or a precursor thereof; and exposing the aerosol to a flame in the chamber which is substantially free of oxidants to form lithium active compound particles. 
     
     
         22 . The process according to  claim 21 , wherein the aerosol is an aerosol of lithium iron phosphate or precursor thereof. 
     
     
         23 . The process according to  claim 21 , wherein the aqueous medium of the lithium active compound or precursor thereof is formed from any one of lithium acetate, lithium hydroxide, lithium nitrate, lithium oxalate, lithium oxide, lithium phosphate, lithium dihydrogen phosphate, lithium carbonate, iron sulfate, iron acetate, iron oxalate, iron citrate, or iron chloride. 
     
     
         24 . The process according to  claim 21 , further comprising collecting the lithium active compound particles as a film on a substrate. 
     
     
         25 . The process according to  claim 21 , further comprising forming a second aerosol of carbon particles in the chamber; and combining the lithium active compound particles with the carbon particles in the chamber to form a composite material. 
     
     
         26 . The process according to  claim 25 , wherein the carbon particles are formed by atomizing a suspension of carbon particles in a liquid medium. 
     
     
         27 . The process according to  claim 21 , further comprising mixing carbon with the lithium active compound particles and depositing the mixture on a substrate to form a cathode electrode.