Materials and Methods of Producing Lithium Cobalt Oxide Materials of A Battery Cell

Abstract

Various lithium cobalt oxides materials doped with one or more metal dopants having a chemical formula of Lix Coy Oz (doped Me1a Me2b Me3c . . . MeNn), and method and apparatus of producing the various lithium cobalt oxides materials are provided. The method includes adjusting a molar ratio MLiSalt:MCoSalt:MMe1Salt:MMe2Salt:MMe3Salt: . . . MMeNSalt of a lithium-containing salt, a cobalt-containing salt and one or more metal-dopant-containing salts within a liquid mixture to be equivalent to a ratio of x:y:a:b:c: . . . n, drying a mist of the liquid mixture in the presence of a gas to form a gas-solid mixture, separating the gas-solid mixture into one or more solid particles of an oxide material, and annealing the solid particles of the oxide material in the presence of another gas flow to obtain crystalized particles of the lithium cobalt oxide material. The process system has a mist generator, a drying chamber, one or more gas-solid separator, and one or more reactors.

1 . An oxide material, comprising:
 a lithium cobalt oxide material doped with at least one metal dopant (Li x  Co y  O z . doped Me a ), wherein x is from 0.9 to 1.1 (0.9≤x≤1.1), y is from 0.9 to 1.1 (0.9≤y≤1.1), z is from 1.8 to 2.2 (1.8≤z≤2.2), and wherein 0<a≤0.05, being obtained from a process comprising:
 forming a mist of a liquid mixture, where the liquid mixture comprises:
 a lithium-containing salt; 
 a cobalt-containing salt; and 
 at least one metal-dopant-containing salt; 
 
 mixing the mist of the liquid mixture with a first gas flow to form a gas-liquid mixture; 
 drying the gas-liquid mixture to form a gas-solid mixture; 
 separating the gas-solid mixture into one or more solid particles of an oxide material; and 
 annealing the one or more solid particles of the oxide material at an annealing temperature of 400° C. or higher to obtain crystalized particles of the lithium cobalt oxide material doped with at least one metal dopant (Li x  Co y  O z .doped Me a ). 
   
     
     
         2 . The oxide material of  claim 1 , wherein the lithium-containing salt is selected from a group consisting of 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), and combinations thereof. 
     
     
         3 . The oxide material of  claim 1 , wherein the cobalt-containing salt is selected from a group consisting of cobalt sulfate (COSO 4 ), cobalt nitrate (Co(NO 3 ) 2 ), cobalt acetate (Co(CH 2 COO) 2 ), cobalt formate (Co(CHO 2 ) 2 ), cobalt chloride (CoCl 2 ), and combinations thereof. 
     
     
         4 . The oxide material of  claim 1 , wherein the at least one metal dopant is selected from a group consisting of Al, Mg, Mn, Zr, Zn, Nb, La, Ce, Sn, Ga, Ba, Ac, Ca, Sc, Ti, V, Cr, Fe, Cu, B, Ge, As, Hf, Mo, W, Re, Ru, Rh, Pt, Ag, Os, Ir, Au, and combinations thereof. 
     
     
         5 . The oxide material of  claim 1 , wherein the at least one metal-dopant-containing salt is selected from a group consisting of magnesium nitrate Mg(NO 3 ) 2 , magnesium acetate (MgAc, Mg(CH 3 COO) 2 ), magnesium chloride (MgCl 2 ), magnesium sulfate (MgSO 4 ), magnesium formate (C 2 H 2 MgO 4 ), aluminum nitrate (Al(NO 3 ) 3 ), aluminum acetate (AlAc, C 6 H 9 AlO 6 ), aluminum chloride (AlCl 3 ), aluminum sulfate (Al 2 (SO 4 ) 3 ), aluminum formate (Al(HCOO) 3 ), manganese sulfate (MnSO 4 ), manganese nitrate (Mn(NO 3 ) 2 ), manganese acetate (Mn(CH 2 COO) 2 ), manganese formate (Mn(CHO 2 ) 2 ), manganese chloride (MnCl 2 ), zirconium nitrate (Zr(NO 3 ) 4 ), zirconium acetate (C 8 H 12 O 8 Zr), zirconium chloride (ZrCl 4 ), zirconium sulfate (Zr(SO 4 ) 2 ), zirconium formate (C 4 H 4 O 8 Zr), nickel sulfate (NiSO 4 ), nickel nitrate (Ni(NO 3 ) 2 ), nickel acetate (Ni(CH 2 COO) 2 ), nickel formate (Ni(CHO 2 ) 2 ), nickel chloride (NiCl 2 ), titanyl nitrate ((TiO(NO 3 ) 2 )), magnesium (Mg)-containing compound, aluminum (Al)-containing compound, titanium (Ti)-containing compound, sodium (Na)-containing compound, potassium (K)-containing compound, scandium (Sc)-containing compound, niobium (Nb)-containing compound, neodymium (Nd)-containing compound, lanthanum (La)-containing compound, cerium (Ce)-containing compound, silicon (Si)-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, manganese (Mn)-containing compound, zirconium (Zr)-containing compound, zinc (Zn)-containing compound, tin (Sn)-containing compound, gallium (Ga)-containing compound, barium (Ba)-containing compound, actinium (Ac)-containing compound, calcium (Ca)-containing compound, iron (Fe)-containing compound, boron (B)-containing compound, germanium (Ge)-containing compound, arsenic (As)-containing compound, hafnium (Hf)-containing compound, Molybdenum (Mo)-containing compound, tungsten (W)-containing compound, rhenium (Re)-containing compound, ruthenium (Ru)-containing compound, rhodium (Rh)-containing compound, platinum (Pt)-containing compound, silver (Ag)-containing compound, osmium (Os)-containing compound, iridium (Ir)-containing compound, gold (Au)-containing compound. 
     
     
         6 . The oxide material of  claim 1 , wherein the lithium cobalt oxide material doped with the at least one metal dopant (LixCo y O z .doped Me a ), is obtained from adjusting a molar ratio M LiSalt :M CoSalt :M MeSalt  of the lithium-containing salt, the cobalt-containing salt, and the at least one metal-dopant-containing salts in the liquid mixture to be a ratio of about x:y:a for making the lithium cobalt oxide material doped with at least one metal dopant (Me) at desirable atomic ratio of Li:Co:Me equaling to x:y:a. 
     
     
         7 . The oxide material of  claim 6 , wherein the adjusting of the molar ratio M LiSalt :M CoSalt :M MeSalt  of the lithium-containing salt, the cobalt-containing salt, and the at least one metal-dopant-containing salt is performed prior to forming the mist of the liquid mixture. 
     
     
         8 . The oxide material of  claim 6 , wherein the adjusting of the molar ratio M LiSalt :M CoSalt :M MeSalt  of the lithium-containing salt, the cobalt-containing salt, and the at least one metal-dopant-containing salt is performed simultaneously with the forming the mist of the liquid mixture. 
     
     
         9 . The oxide material of  claim 1 , wherein the liquid mixture is soluble in a suitable solvent and the suitable solvent is selected from a group consisting of water, alcohol, methanol, isopropyl alcohol, organic solvents, inorganic solvents, organic acids, sulfuric acid (H 2 SO 4 ), citric acid (C 6 H 8 O 7 ), acetic acids (CH 3 COOH), butyric acid (C 4 HO 2 ), lactic acid (C 3 H 6 O 3 ), nitric acid (HNO 3 ), hydrochloric acid (HCl), ethanol, pyridine, ammonia, acetone, and combinations thereof. 
     
     
         10 . The oxide material of  claim 1 , wherein the one or more solid particles of the oxide material are annealed in the presence of a second gas flow that is heated to 550° C. or higher and the second gas flow is delivered into a reaction chamber to maintain the annealing temperature inside the reaction chamber. 
     
     
         11 . The oxide material of  claim 1 , wherein the one or more solid particles of the oxide material are annealed in the presence of the second gas flow inside a reaction chamber and the annealing temperature inside the reaction chamber is maintained via a heating element coupled to the reaction chamber. 
     
     
         12 . The oxide material of  claim 1 , wherein the liquid mixture is dried in the presence of the first gas that is heated to 200° C. or higher inside a drying chamber and the first gas is delivered into the drying chamber to maintain a drying temperature inside the drying chamber. 
     
     
         13 . The oxide material of  claim 1 , wherein the liquid mixture is dried inside a drying chamber and a drying temperature inside the drying chamber is maintained via a heating element coupled to the drying chamber. 
     
     
         14 . An oxide material, comprising:
 a lithium cobalt oxide material doped with one or more metal dopants (Li x  Co y  O z . doped Me1 a , Me2 b , Me3 c , . . . MeN n ), wherein x is from 0.9 to 1.1 (0.9≤x≤1.1), y is from 0.9 to 1.1 (0.9≤y≤1.1), z is from 1.8 to 2.2 (1.8≤z≤2.2), and wherein N≥1, and each a, b, c, . . . , n is more than 0 and no more than 0.05, being obtained from a process comprising:   adjusting a molar ratio M LiSalt :M CoSalt :M Me1Salt :M Me2Salt :M Me3Salt : . . . M MeNSalt  of a lithium-containing salt, a cobalt-containing salt, and one or more metal-dopant-containing salts which are soluble in a suitable solvent into a liquid mixture, wherein each of the one or more metal-dopant-containing salts is selected from a group consisting of a first metal-containing salt, a second metal-containing salt, a third metal-containing salt, . . . an N metal-containing salt and combinations thereof, and forming a mist of the liquid mixture;   mixing the mist of the liquid mixture with a gas flow to form a gas-liquid mixture;   drying the gas-liquid mixture to form a gas-solid mixture;   separating the gas-solid mixture into one or more solid particles of an oxide material; and   annealing the one or more solid particles of the oxide material at an annealing temperature of 400° C. or higher to obtain crystalized particles of the lithium cobalt oxide material doped with one or more metal dopants.   
     
     
         15 . The oxide material of  claim 14 , wherein the lithium-containing salt is selected from a group consisting of 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), and combinations thereof. 
     
     
         16 . The oxide material of  claim 14 , wherein the cobalt-containing salt is selected from a group consisting of cobalt sulfate (COSO 4 ), cobalt nitrate (Co(NO 3 ) 2 ), cobalt acetate (Co(CH 2 COO) 2 ), cobalt formate (Co(CHO 2 ) 2 ), cobalt chloride (CoCl 2 ), and combinations thereof. 
     
     
         17 . The oxide material of  claim 14 , wherein each of the one or more metal dopants is selected from a group consisting of Al, Mg, Mn, Zr, Zn, Nb, La, Ce, Sn, Ga, Ba, Ac, Ca, Sc, Ti, V, Cr, Fe, Cu, B, Ge, As, Hf, Mo, W, Re, Ru, Rh, Pt, Ag, Os, Ir, Au, and combinations thereof. 
     
     
         18 . The oxide material of  claim 14 , wherein each of the one or more metal-dopant-containing salts is selected from a group consisting of magnesium nitrate Mg(NO 3 ) 2 , magnesium acetate (MgAc, Mg(CH 3 COO) 2 ), magnesium chloride (MgCl 2 ), magnesium sulfate (MgSO 4 ), magnesium formate (C 2 H 2 MgO 4 ), aluminum nitrate (Al(NO 3 ) 3 ), aluminum acetate (AlAc, C 6 H 9 AlO 6 ), aluminum chloride (AlCl 3 ), aluminum sulfate (Al 2 (SO 4 ) 3 ), aluminum formate (Al(HCOO) 3 ), manganese sulfate (MnSO 4 ), manganese nitrate (Mn(NO 3 ) 2 ), manganese acetate (Mn(CH 2 COO) 2 ), manganese formate (Mn(CHO 2 ) 2 ), manganese chloride (MnCl 2 ), zirconium nitrate (Zr(NO 3 ) 4 ), zirconium acetate (C 8 H 12 O 8 Zr), zirconium chloride (ZrCl 4 ), zirconium sulfate (Zr(SO 4 ) 2 ), zirconium formate (C 4 H 4 O 8 Zr), nickel sulfate (NiSO 4 ), nickel nitrate (Ni(NO 3 ) 2 ), nickel acetate (Ni(CH 2 COO) 2 ), nickel formate (Ni(CHO 2 ) 2 ), nickel chloride (NiCl 2 ), titanyl nitrate ((TiO(NO 3 ) 2 )), magnesium (Mg)-containing compound, aluminum (Al)-containing compound, titanium (Ti)-containing compound, sodium (Na)-containing compound, potassium (K)-containing compound, scandium (Sc)-containing compound, niobium (Nb)-containing compound, neodymium (Nd)-containing compound, lanthanum (La)-containing compound, cerium (Ce)-containing compound, silicon (Si)-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, manganese (Mn)-containing compound, zirconium (Zr)-containing compound, zinc (Zn)-containing compound, tin (Sn)-containing compound, gallium (Ga)-containing compound, barium (Ba)-containing compound, actinium (Ac)-containing compound, calcium (Ca)-containing compound, iron (Fe)-containing compound, boron (B)-containing compound, germanium (Ge)-containing compound, arsenic (As)-containing compound, hafnium (Hf)-containing compound, Molybdenum (Mo)-containing compound, tungsten (W)-containing compound, rhenium (Re)-containing compound, ruthenium (Ru)-containing compound, rhodium (Rh)-containing compound, platinum (Pt)-containing compound, silver (Ag)-containing compound, osmium (Os)-containing compound, iridium (Ir)-containing compound, gold (Au)-containing compound. 
     
     
         19 . The oxide material of  claim 14 , wherein the adjusting of the molar ratio M LiSalt :M CoSalt :M Me1Salt :M Me2Salt :M Me3Salt : . . . M MeNSalt  of the lithium-containing salt, the cobalt-containing salt, and the one or more metal-dopant-containing salts is performed prior to forming the mist of the liquid mixture. 
     
     
         20 . The oxide material of  claim 14 , wherein the adjusting of the molar ratio M LiSalt :M CoSalt :M Me1Salt :M Me2Salt :M Me3Salt :M MeNSalt  of the lithium-containing salt, the cobalt-containing salt, and the one or more metal-dopant-containing salts is performed simultaneously in forming the mist of the liquid mixture. 
     
     
         21 . The oxide material of  claim 14 , wherein the suitable solvent is selected from a group consisting of water, alcohol, methanol, isopropyl alcohol, organic solvents, inorganic solvents, organic acids, sulfuric acid (H 2 SO 4 ), citric acid (C 6 H 8 O 7 ), acetic acids (CH 3 COOH), butyric acid (C 4 H 8 O 2 ), lactic acid (C 3 H 6 O 3 ), Nitric acid (HNO 3 ), hydrochloric acid (HCl), ethanol, pyridine, ammonia, acetone, and combinations thereof. 
     
     
         22 . An oxide material, comprising:
 a lithium cobalt oxide material doped with at least one metal dopant (Li x  Co y  O z .doped Me a ), wherein x is from 0.9 to 1.1 (0.9≤x≤1.1), y is from 0.9 to 1.1 (0.9≤y≤1.1), z is from 1.8 to 2.2 (1.8≤z≤2.2), and wherein 0<a≤0.05, being obtained from a process comprising:
 adjusting a molar ratio M LiSalt :M CoSalt :M Me Salt  of a lithium-containing salt, a cobalt-containing salt, and at least one metal-dopant-containing salt into a liquid mixture and forming a mist of the liquid mixture, where the liquid mixture comprises:
 the lithium-containing salt; 
 the cobalt-containing salt; 
 the at least one metal-dopant-containing salt; and 
 a suitable solvent; 
 
 mixing the mist of the liquid mixture with a gas flow to form a gas-liquid mixture; 
 drying the gas-liquid mixture to form one or more solid particles of an oxide material; and 
 annealing the one or more solid particles of the oxide material at an annealing temperature of 400° C. or higher to obtain crystalized particles of the lithium cobalt oxide material doped with at least one metal dopant (Li x  Co y  O z .doped Me a ).