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 process comprising forming a gas-solid mixture from one or more flows of a gas from a first gas source and one or more solid particles of an oxide material with two or more metals inside a reaction chamber; reacting the gas-solid mixture inside the reaction chamber; and oxidizing the gas-solid mixture into the reaction product, wherein the one or more solid particles of the oxide material with two or more metals are obtained from drying a gas-liquid mixture formed from one or more gases from a second gas source and a mist of a liquid mixture from a mist generator inside a drying chamber.   
     
     
         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 at least 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, sodium iron oxide, 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. 
     
     
         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 two or more metal-containing precursors, a gel mixture of two or more metal-containing precursors, and combinations thereof. 
     
     
         6 . The material of  claim 5 , wherein each of the two or more metal-containing precursors 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 (Al)-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 oxidized solid particles, wherein the one or more oxidized solid particles comprise a lithium metal oxide material comprising lithium (Li), and at least 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, and wherein the one or more oxidized solid particles are obtained from a first process comprising flowing one or more flows of a gas from a first gas source into a reaction chamber; forming a gas-solid mixture from the one or more flows of a gas and one or more solid lithium-containing materials inside the reaction chamber; and oxidizing the gas-solid mixture into the oxidized solid particles and reacting the gas-solid mixture inside the reaction chamber,   wherein the one or more solid lithium-containing materials are obtained from forming a second process comprising forming a liquid mixture from one or more lithium-containing precursors and one or more metal-containing precursors; generating a mist of desired liquid droplet sizes of the liquid mixture from a mist generator inside a drying chamber; flowing one or more gases from second gas source into the drying chamber; and drying a gas-liquid mixture formed from the one or more gases and the mist inside the drying chamber to obtain the one or more solid lithium-containing materials.   
     
     
         12 . The material of  claim 11 , wherein the lithium metal oxide material comprise an oxide material selected from the group consisting of lithium titanium oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel oxide, a lithium 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 Cs), Li a (Ni x Mn y Co z )MeO b F c  (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or Cs), lithium cobalt aluminum oxide, lithium nickel cobalt aluminum oxide, and combinations thereof. 
     
     
         13 . 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 two or more metal-containing precursors, a gel mixture of two or more metal-containing precursors, and combinations thereof. 
     
     
         14 . The material of  claim 13 , wherein each of the two or more metal-containing precursors 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 (Al)-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. 
     
     
         15 . A material of a battery cell, comprising:
 one or more oxidized solid particles, wherein the one or more oxidized solid particles comprise a lithium metal oxide material comprising lithium (Li), and at least 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, and wherein the one or more oxidized solid particles are obtained from a first process comprising flowing one or more flows of a gas from a first gas source into a reaction chamber; forming a gas-solid mixture from the one or more flows of the gas and one or more solid lithium-containing materials inside the reaction chamber; oxidizing the gas-solid mixture into the oxidized solid particles for a oxidizing residence time period and reacting the gas-solid mixture inside the reaction chamber,   wherein the one or more solid lithium-containing materials are obtained from a second process comprising forming a liquid mixture from two or more metal-containing precursors; delivering the liquid mixture into a drying chamber; flowing one or more gases from second gas source into the drying chamber; generating a mist of desired liquid droplet sizes of the liquid mixture from a mist generator; forming a gas-liquid mixture from the one or more gases and the mist; drying and reacting the gas-liquid mixture with additional one more gases inside the drying chamber for a drying time period; obtaining a dried mixture from the drying chamber; and separating the dried mixture into a gaseous side product and the one or more solid lithium-containing materials from a gas-solid separator.   
     
     
         16 . The material of  claim 15 , wherein the lithium metal oxide material comprise an oxide 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, sodium iron oxide, 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. 
     
     
         17 . The material of  claim 15 , 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 two or more metal-containing precursors, a gel mixture of two or more metal-containing precursors, and combinations thereof. 
     
     
         18 . The material of  claim 15 , wherein each of the two or more 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 (Al)-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. 
     
     
         19 . The material of  claim 15 , 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. 
     
     
         20 . The material of  claim 15 , 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.