Method of Preparing a Material of a Battery Cell

Abstract

A continuous process for producing a material of a battery cell using a system having a mist generator, a drying chamber, one or more gas-solid separators and a reactor is provided. A mist generated from a liquid mixture of two or more metal precursor compounds in desired ratio is dried inside the drying chamber. Heated air or gas is served as the gas source for forming various gas-solid mixtures and as the energy source for reactions inside the drying chamber and the reactor. One or more gas-solid separators are used in the system to separate gas-solid mixtures from the drying chamber into solid particles mixed with the metal precursor compounds and continuously deliver the solid particles into the reactor for further reaction to obtain final solid material particles with desired crystal structure, particle size, and morphology.

What is claimed: 
     
         1 . A material of a battery cell, comprising:
 one or more final solid particles of a reaction product, wherein the reaction product is obtained from a method, which includes:
 drying a first gas-solid mixture formed from a flow of a first gas and a mist of a liquid mixture inside a first chamber; 
 obtaining a first type of solid particles from the first gas-solid mixture; 
 delivering the first type of solid particles into a second chamber; 
 forming a second gas-solid mixture from a flow of a second gas and the first type of solid particles inside the second chamber; 
 reacting the second gas-solid mixture inside the second chamber and oxidizing the second gas-solid mixture into the reaction product; and 
 obtaining a second type of solid particles from the reaction product. 
   
     
     
         2 . The material of  claim 1 , wherein the one or more final solid particles comprise an oxide compound with two or more metals comprising lithium (Li), and a metal selected from the group consisting of cobalt (Co), manganese (Mn), nickel (Ni), aluminum (Al), magnesium (Mg), titanium (Ti), sodium (Na), potassium (K), rubidium (Rb), vanadium (V), cesium (Cs), chromium (Cr), copper (Cu), iron (Fe), and combinations thereof. 
     
     
         3 . The material of  claim 1 , wherein the one or more final solid particles comprise a material selected from the group consisting of a metal oxide, titanium oxide, chromium oxide, tin oxide, copper oxide, aluminum oxide, manganese oxide, iron oxide, a metal oxide with two or more metals, lithium transitional metal oxides, lithium titanium oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel oxide, lithium iron phosphate, lithium cobalt phosphate, lithium manganese phosphate, lithium nickel phosphate, sodium iron oxide, sodium iron phosphate, a metal oxide with three or four intercalated metals, lithium nickel cobalt oxide, lithium nickel manganese oxide, lithium nickel manganese cobalt oxide, Li a Ni b Mn c Co d O e  in layered structures, Li a Ni b Mn c Co d O e  in layered-layered structures, LiNi x Mn y Co z O 2  (where x+y+z=1), LiNi 0.33 Mn 0.33 Co 0.33 O 2 , LiNi 0.6 Mn 0.2 Co 0.2 O 2 , LiNi 0.5 Mn 0.3 Co 0.2 O 2 , LiNi 0.4 Mn 0.4 Co 0.2 O 2 , LiNi 0.1 Mn 0.15 Co 0.15 O 2 , LiNi 0.8 Mn 0.1 Co 0.1 O 2 , a mixed metal oxide with doped metal, Li a (Ni x Mn y Co)MeO b (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), Li a (Ni x Mn y Co z )MeO b F c  (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), lithium cobalt aluminum oxide, lithium nickel cobalt aluminum oxide, sodium iron manganese oxide, and combinations thereof. 
     
     
         4 . The material of  claim 1 , wherein the one or more final solid particles are obtained from separating the reaction product into the one or more final solid particles and a gaseous side product using one or more separators selected from the group consisting of cyclones, electrostatic separators, electrostatic precipitators, gravity separators, inertia separators, membrane separators, fluidized beds, classifiers, electric sieves, impactors, particles collectors, leaching separators, elutriators, air classifiers, leaching classifiers, and combination thereof. 
     
     
         5 . The material of  claim 1 , wherein the liquid mixture is selected from the group consisting of a solution of two or more metal-containing precursors, a slurry of metal-containing precursors, a gel mixture of metal-containing precursors, and combinations thereof. 
     
     
         6 . The material of  claim 5 , wherein the metal-containing precursor comprises a metal-containing compound selected from the group consisting of metal salts, lithium-containing compound, cobalt-containing compound, manganese-containing compound, nickel-containing compound, lithium sulfate (Li 2 SO 4 ), lithium nitrate (LiNO 3 ), lithium carbonate (Li 2 CO 3 ), lithium acetate (LiCH 2 COO), lithium hydroxide (LiOH), lithium formate (LiCHO 2 ), lithium chloride (LiCl), cobalt sulfate (CoSO 4 ), cobalt nitrate (Co(NO 3 ) 2 ), cobalt carbonate (CoCO 3 ), cobalt acetate (Co(CH 2 COO) 2 ), cobalt hydroxide (Co(OH) 2 ), cobalt formate (Co(CHO 2 ) 2 ), cobalt chloride (CoCl 2 ), manganese sulfate (MnSO 4 ), manganese nitrate (Mn(NO 3 ) 2 ), manganese carbonate (MnCO 3 ), manganese acetate (Mn(CH 2 COO) 2 ), manganese hydroxide (Mn(OH) 2 ), manganese formate (Mn(CHO 2 ) 2 ), manganese chloride (MnCl 2 ), nickel sulfate (NiSO 4 ), nickel nitrate (Ni(NO 3 ) 2 ), nickel carbonate (NiCO 3 ), nickel acetate (Ni(CH 2 COO) 2 ), nickel hydroxide (Ni(OH) 2 ), nickel formate (Ni(CHO 2 ) 2 ), nickel chloride (NiCl 2 ), aluminum (AI)-containing compound, titanium (Ti)-containing compound, sodium (Na)-containing compound, potassium (K)-containing compound, rubidium (Rb)-containing compound, vanadium (V)-containing compound, cesium (Cs)-containing compound, chromium (Cr)-containing compound, copper (Cu)-containing compound, magnesium (Mg)-containing compound, iron (Fe)-containing compound, and combinations thereof. 
     
     
         7 . The material of  claim 1 , wherein the one or more gases inside the drying chamber are heated to a first temperature and the one or more gases inside the reaction chamber is heated to a second temperature, and wherein the second temperature is higher than the first temperature. 
     
     
         8 . The material of  claim 1 , wherein the mixture of the one or more gases and the mist comprises a gas selected from the group consisting of air, oxygen, carbon dioxide, nitrogen gas, inert gas, noble gas, and combinations thereof and the gas is heated to a temperature of between 70° C. and 600° C. 
     
     
         9 . The material of  claim 1 , wherein the one or more flows of the gas comprise a gas selected from the group consisting of air, oxygen, carbon dioxide, an oxidizing gas, nitrogen gas, inert gas, noble gas, and combinations thereof and the gas is heated to a temperature of between 400° C. and 1300° C. 
     
     
         10 . The material of  claim 1 , wherein the mist is generated at desired liquid droplet sizes of between one tenth of a micron and one millimeter. 
     
     
         11 . A material of a battery electrochemical cell, comprising:
 one or more final solid particles of a reaction product, wherein the reaction product is obtained from a method, which includes:
 forming a liquid mixture from two or more metal-containing precursors; 
 delivering the liquid mixture into a process system comprising:
 a first chamber; and 
 a second chamber; 
 
 flowing a flow of a first gas into the first chamber of the process system; 
 generating a mist of desired liquid droplet sizes from the liquid mixture; 
 forming a gas-liquid mixture from the first gas and the mist of the liquid mixture and drying and reacting the gas-liquid mixture for a first residence time inside the first chamber to form a first gas-solid mixture; 
 obtaining a first type of solid particles from the first gas-solid mixture and delivering the first type of solid particles into the second chamber of the process system; 
 flowing a flow of a second gas inside the second chamber; 
 forming a second gas-solid mixture from the second gas and the first type of solid particles inside the second chamber; 
 reacting the second gas-solid mixture inside the second chamber for a second residence time and oxidizing the second gas-solid mixture into a reaction product; and 
 obtaining a second type of solid particles from the reaction product. 
   
     
     
         12 . The material of  claim 11 , wherein the one or more final solid particles of the reaction product comprise an oxide compound with two or more metals comprising lithium (Li), and a metal selected from the group consisting of cobalt (Co), manganese (Mn), nickel (Ni), aluminum (Al), magnesium (Mg), titanium (Ti), sodium (Na), potassium (K), rubidium (Rb), vanadium (V), cesium (Cs), chromium (Cr), copper (Cu), iron (Fe), and combinations thereof. 
     
     
         13 . The material of  claim 11 , wherein the one or more final solid particles comprise a material selected from the group consisting of a metal oxide, titanium oxide, chromium oxide, tin oxide, copper oxide, aluminum oxide, manganese oxide, iron oxide, a metal oxide with two or more metals, lithium transitional metal oxides, lithium titanium oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel oxide, lithium iron phosphate, lithium cobalt phosphate, lithium manganese phosphate, lithium nickel phosphate, sodium iron oxide, sodium iron phosphate, a metal oxide with three or four intercalated metals, lithium nickel cobalt oxide, lithium nickel manganese oxide, lithium nickel manganese cobalt oxide, Li a Ni b Mn c Co d O e  in layered structures, Li a Ni b Mn c Co d O e  in layered-layered structures, LiNi x Mn y Co z O 2  (where x+y+z=1), LiNi 0.33 Mn 0.33 Co 0.33 O 2 , LiNi 0.5 Mn 0.2 Co 0.2 O 2 , LiNi 0.5 Mn 0.3 Co 0.2 O 2 , LiNi 0.4 Mn 0.4 Co 0.2 O 2 , LiNi 0.7 Mn 0.15 Co 0.15 O 2 , LiNi 0.8 Mn 0.1 Co 0.1 O 2 , a mixed metal oxide with doped metal, Li a (Ni x Mn y Co z )MeO b (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), Li a (Ni x Mn y Co z )MeO b F c  (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), lithium cobalt aluminum oxide, lithium nickel cobalt aluminum oxide, sodium iron manganese oxide, and combinations thereof. 
     
     
         14 . The material of  claim 11 , wherein the mist is generated at the desired liquid droplet sizes of between one tenth of a micron and one millimeter, and wherein the liquid mixture is selected from the group consisting of a solution of two or more metal-containing precursors, a slurry of metal-containing precursors, a gel mixture of metal-containing precursors, and combinations thereof. 
     
     
         15 . The material of  claim 14 , wherein the metal-containing precursor comprises a metal-containing compound selected from the group consisting of metal salts, lithium-containing compound, cobalt-containing compound, manganese-containing compound, nickel-containing compound, lithium sulfate (Li 2 SO 4 ), lithium nitrate (LiNO 3 ), lithium carbonate (Li 2 CO 3 ), lithium acetate (LiCH 2 COO), lithium hydroxide (LiOH), lithium formate (LiCHO 2 ), lithium chloride (LiCl), cobalt sulfate (CoSO 4 ), cobalt nitrate (Co(NO 3 ) 2 ), cobalt carbonate (CoCO 3 ), cobalt acetate (Co(CH 2 COO) 2 ), cobalt hydroxide (Co(OH) 2 ), cobalt formate (Co(CHO 2 ) 2 ), cobalt chloride (CoCl 2 ), manganese sulfate (MnSO 4 ), manganese nitrate (Mn(NO 3 ) 2 ), manganese carbonate (MnCO 3 ), manganese acetate (Mn(CH 2 COO) 2 ), manganese hydroxide (Mn(OH) 2 ), manganese formate (Mn(CHO 2 ) 2 ), manganese chloride (MnCl 2 ), nickel sulfate (NiSO 4 ), nickel nitrate (Ni(NO 3 ) 2 ), nickel carbonate (NiCO 3 ), nickel acetate (Ni(CH 2 COO) 2 ), nickel hydroxide (Ni(OH) 2 ), nickel formate (Ni(CHO 2 ) 2 ), nickel chloride (NiCl 2 ), aluminum (AI)-containing compound, titanium (Ti)-containing compound, sodium (Na)-containing compound, potassium (K)-containing compound, rubidium (Rb)-containing compound, vanadium (V)-containing compound, cesium (Cs)-containing compound, chromium (Cr)-containing compound, copper (Cu)-containing compound, magnesium (Mg)-containing compound, iron (Fe)-containing compound, and combinations thereof. 
     
     
         16 . A material of a battery cell, comprising:
 one or more final solid particles of an oxidized reaction product, wherein the oxidized reaction product is obtained from a method, which includes:
 forming a liquid mixture from two or more metal-containing precursors; 
 delivering the liquid mixture into a process system comprising a first chamber, a second chamber, and one or more gas-solid separators; 
 flowing a flow of a first gas into the first chamber of the process system; 
 generating a mist of desired liquid droplet sizes from the liquid mixture; 
 forming a gas-liquid mixture from the first gas and the mist of the liquid mixture and drying and reacting the gas-liquid mixture for a first residence time inside the first chamber to form a first gas-solid mixture; 
 obtaining a first type of solid particles from the first gas-solid mixture and delivering the first type of solid particles into the second chamber of the process system; 
 flowing a flow of a second gas inside the second chamber; 
 forming a second gas-solid mixture from the second gas and the first type of solid particles inside the second chamber; 
 reacting the second gas-solid mixture inside the second chamber for a second residence time, and oxidizing the second gas-solid mixture into a reaction product; 
 delivering the oxidized reaction product out of the second chamber; 
 cooling the reaction product and separating the reaction product into a second type of solid particles and a gaseous side product using the one or more gas-solid separators of the process system; and 
 obtaining the second type of solid particles. 
   
     
     
         17 . The material of  claim 16 , wherein the one or more final solid particles of the oxidized reaction product comprise an oxide compound with two or more metals comprising lithium (Li), and a metal selected from the group consisting of cobalt (Co), manganese (Mn), nickel (Ni), aluminum (Al), magnesium (Mg), titanium (Ti), sodium (Na), potassium (K), rubidium (Rb), vanadium (V), cesium (Cs), chromium (Cr), copper (Cu), iron (Fe), and combinations thereof. 
     
     
         18 . The material of  claim 16 , wherein the final solid particles comprise a material selected from the group consisting of a metal oxide, titanium oxide, chromium oxide, tin oxide, copper oxide, aluminum oxide, manganese oxide, iron oxide, a metal oxide with two or more metals, lithium transitional metal oxides, lithium titanium oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel oxide, lithium iron phosphate, lithium cobalt phosphate, lithium manganese phosphate, lithium nickel phosphate, sodium iron oxide, sodium iron phosphate, a metal oxide with three or four intercalated metals, lithium nickel cobalt oxide, lithium nickel manganese oxide, lithium nickel manganese cobalt oxide, Li a Ni b Mn c Co d O e  in layered structures, Li a Ni b Mn c Co d O e  in layered-layered structures, LiNi x Mn y Co z O 2  (where x+y+z=1), LiNi 0.33 Mn 0.33 Co 0.33 O 2 , LiNi 0.6 Mn 0.2 Co 0.2 O 2 , LiNi 0.5 Mn 0.3 Co 0.2 O 2 , LiNi 0.4 Mn 0.4 Co 0.2 O 2 , LiNi 0.7 Mn 0.15 Co 0.15 O 2 , LiNi 0.8 Mn 0.1 Co 0.1 O 2 , a mixed metal oxide with doped metal, Li a (Ni x Mn y Co z )MeO b (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), Li a (Ni x Mn y Co z )MeO b F c  (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), lithium cobalt aluminum oxide, lithium nickel cobalt aluminum oxide, sodium iron manganese oxide, and combinations thereof. 
     
     
         19 . The material of  claim 16 , wherein the mist is generated at the desired liquid droplet sizes of between one tenth of a micron and one millimeter, and wherein the liquid mixture is selected from the group consisting of a solution of two or more metal-containing precursors, a slurry of metal-containing precursors, a gel mixture of metal-containing precursors, and combinations thereof. 
     
     
         20 . The material of  claim 16 , wherein the metal-containing precursor comprises a metal-containing compound selected from the group consisting of metal salts, lithium-containing compound, cobalt-containing compound, manganese-containing compound, nickel-containing compound, lithium sulfate (Li 2 SO 4 ), lithium nitrate (LiNO 3 ), lithium carbonate (Li 2 CO 3 ), lithium acetate (LiCH 2 COO), lithium hydroxide (LiOH), lithium formate (LiCHO 2 ), lithium chloride (LiCl), cobalt sulfate (CoSO 4 ), cobalt nitrate (Co(NO 3 ) 2 ), cobalt carbonate (CoCO 3 ), cobalt acetate (Co(CH 2 COO) 2 ), cobalt hydroxide (Co(OH) 2 ), cobalt formate (Co(CHO 2 ) 2 ), cobalt chloride (CoCl 2 ), manganese sulfate (MnSO 4 ), manganese nitrate (Mn(NO 3 ) 2 ), manganese carbonate (MnCO 3 ), manganese acetate (Mn(CH 2 COO) 2 ), manganese hydroxide (Mn(OH) 2 ), manganese formate (Mn(CHO 2 ) 2 ), manganese chloride (MnCl 2 ), nickel sulfate (NiSO 4 ), nickel nitrate (Ni(NO 3 ) 2 ), nickel carbonate (NiCO 3 ), nickel acetate (Ni(CH 2 COO) 2 ), nickel hydroxide (Ni(OH) 2 ), nickel formate (Ni(CHO 2 ) 2 ), nickel chloride (NiCl 2 ), aluminum (AI)-containing compound, titanium (Ti)-containing compound, sodium (Na)-containing compound, potassium (K)-containing compound, rubidium (Rb)-containing compound, vanadium (V)-containing compound, cesium (Cs)-containing compound, chromium (Cr)-containing compound, copper (Cu)-containing compound, magnesium (Mg)-containing compound, iron (Fe)-containing compound, and combinations thereof.