System with power injection module and method thereof

Abstract

A method of producing one or more particles for a metal-containing battery material for a battery cell using a liquid mixture, the method comprising: providing a processing system comprising a reaction chamber, a dispersion chamber having one or more openings, and one or more power jet modules, wherein each power jet module comprises one or more doors; a power injector having an array of two or more nozzle holes on one side of the power injector, through each nozzle hole a liquid mixture is injected into one or more streams of droplets into the dispersion chamber, where the liquid mixture comprises a lithium-containing compound and one or more metal-containing compounds; moving one or more power jet modules to be in a jet position; one or more doors on one or more power jet modules are opened; one or more streams of droplets within a reaction chamber of a processing system are processed into one or more particles of a metal-containing battery material.

Description

[0001] This application is a divisional application of the Chinese patent application with application number 202080043828.9, application date June 25, 2020, and invention name “System with power injection module and method thereof”. Technical Field

[0002] The present invention generally relates to the preparation of materials for battery applications. More specifically, the present invention relates to methods and systems for making structured cathode or anode active materials for secondary batteries. Background Art

[0003] Considerable efforts have been made to develop advanced electrochemical battery cells to meet the growing demands for high energy density, high power performance, high capacity, long cycle life, low price and excellent safety for various consumer electronics, electric transportation and grid energy storage applications. In most cases, miniaturized, lightweight and rechargeable (and thus reusable) batteries are required to save space and material resources.

[0004] In an electrochemically active battery cell, the cathode and anode are immersed in an electrolyte and are electrically separated by a separator. The separator is usually made of a porous polymer membrane material so that during battery charging and discharging, the metal ions released from the electrode into the electrolyte can diffuse through the pores of the separator and migrate between the cathode and the anode. The type of battery cell is usually named according to the metal ions transported between its cathode and anode electrodes. Over the years, a variety of rechargeable secondary batteries have been developed commercially, such as nickel-cadmium batteries, nickel-metal hydride batteries, lead-acid batteries, lithium-ion batteries, and lithium-ion polymer batteries. In order to be used commercially, rechargeable secondary batteries require high energy density, high power performance, and safety. However, there is a certain trade-off between energy density and power performance.

[0005] Lithium-ion battery is a secondary battery developed in the early 1990s. Compared with other secondary batteries, it has the advantages of high energy density, long cycle life, no memory effect, low self-discharge rate and environmental friendliness. Lithium-ion battery was quickly accepted and dominated the commercial secondary battery market. However, the cost of materials for commercial production of many types of lithium-ion batteries is much higher than that of other types of secondary batteries.

[0006] In lithium-ion batteries, the electrolyte is mainly composed of lithium salts (such as LiPF6, LiBF4 or LiClO4) in organic solvents (such as ethylene carbonate, dimethyl carbonate and diethyl carbonate) so that lithium ions can move freely therein. Typically, aluminum foil (such as 15 to 20 microns thick) and copper foil (such as 8 to 15 microns thick) are used as collectors for cathode electrodes and anode electrodes, respectively. For the anode, micron-sized graphite (with a reversible capacity of about 330 mAh / g) is often used as the active material covering the anode collector. Graphite materials are often prepared by solid-state processes, such as grinding and pyrolysis (such as graphitization at about 3000°C) in the absence of oxygen and at extremely high temperatures. As for active cathode materials, a variety of solid materials with different crystal structures and capacities have been developed over the years. Examples of good cathode active materials include nano- or micron-sized lithium transition metal oxide materials and lithium ion phosphates.

[0007] The cathode active material is the most expensive component in lithium-ion batteries and determines the energy density, cycle life, production cost and safety of lithium battery cells to a relatively large extent. When lithium batteries were first commercialized, lithium cobalt oxide (LiCoO2) material was used as the cathode material, and it still has a significant market share in the anion active material market. However, cobalt is toxic and expensive. Other lithium transition metal oxide materials, such as layered LiMeO2 (wherein metal Me = Ni, Mn, Co, etc.; e.g. LiNi 0.33 Mn 0.33 Co 0.33 O2, whose reversible / actual capacity is about 140-150 mAh / g), spinel-structured LiMn2O4 (whose reversible / actual capacity is about 110-120 mAh / g) and olive-tree-type lithium metal phosphates (such as LiFePO4, whose reversible / actual capacity is about 140-150 mAh / g) have recently been developed as active anion materials. When used as anion materials, spinel-structured LiMn2O4 materials exhibit poor battery cycle cycles, while olive-tree-type LiFePO4 materials suffer from low energy density and poor low-temperature performance. As for LiMeO2 materials, although their electrochemical properties are good, the existing preparation process of LiMeO2 will mainly obtain agglomerates, making the electrode density of most LiMeO2 materials lower than that of LiCoO2. In any case, the existing processes for preparing battery application materials (especially cathode active materials) are too expensive because most of the processes consume too much time and energy, and the quality of existing materials is still inconsistent and the yield is low.

[0008] Conventional material preparation processes such as solid-state reactions (e.g., mixing solid precursors and then calcining) and wet chemical processes (e.g., treating precursors in a solution by coprecipitation, sol-gel or hydrothermal reaction, followed by mixing and calcining) face significant challenges in producing nano- or microstructured materials. It is difficult to consistently produce uniform solid materials (i.e., particles and powders) with the desired particle size, morphology, crystal structure, particle shape, and even stoichiometric ratio. For complete reaction, isomorphism, and grain growth, most conventional solid-state reactions require long calcination times (e.g., 4-20 hours) and additional annealing processes. For example, spinel-structured LiMn2O4 and olive-tree-type LiFePO4 materials prepared by solid-state reactions require at least several hours of calcination and separate post-heating annealing processes (e.g., 24 hours), and still show poor quality consistency. An inherent problem with solid-state reactions is the presence of temperature and chemical (e.g., O2) gradients in the calcining furnace, which limits the performance, consistency, and overall quality of the final product.

[0009] On the other hand, wet chemical processes performed at low temperatures generally involve faster chemical reactions, but still require a separate high temperature calcination process or even an additional annealing process afterwards. In addition, the chemical additives, gelling agents and surfactants required in the wet chemical process will increase the material production cost (purchase of additional chemicals and adjustment of specific process sequences, rates, pH and temperatures), and may interfere with the final composition of the active material produced thereby (thus additional steps are generally required to remove unwanted chemicals or filter products). In addition, the primary particles of the product powders produced by wet chemistry are very small in size and tend to agglomerate into undesirable large-sized secondary particles, thereby affecting the energy storage density. In addition, the morphology of the powder particles produced thereby often exhibits undesirable amorphous agglomerates, multi-hole agglomerates, linear bodies, rod-shaped bodies, flake bodies, etc. Uniform particle size and morphology that allow high storage density are desirable.

[0010] The synthesis of lithium cobalt oxide (LiCoO2) materials is relatively simple, involving mixing lithium salts (e.g., lithium hydroxide (LiOH) or lithium carbonate (Li2CO3) with cobalt oxide (Co3O4) of the desired particle size, followed by calcination in a furnace at very high temperatures for a long time (e.g., 20 hours at 900°C) to ensure that the lithium metal diffuses into the crystal structure of the cobalt oxide to form a suitable final product of a layered crystal structured LiCoO2 powder. This method is not suitable for LiMeO2 because transition metals such as Ni, Mn, and Co cannot diffuse well into each other to form a uniformly mixed transition metal layer if the transition metal oxides or salts are directly mixed and reacted (solid state calcination). Therefore, before preparing the final active anion material (e.g., lithium NiMnCo transition metal oxide (LiMeO2)), the conventional LiMeO2 preparation process requires the purchase or preparation of transition metal hydroxide precursor compounds (e.g., Me(OH)2, Me=Ni, Mn, Co, etc.) from a co-precipitation wet chemical process.

[0011] Since these Ni(OH)2, Co(OH)2 and Mn(OH)2 precursor compounds have different water solubilities and they are usually precipitated at different concentrations, the pH of the mixed solution of these precursor compounds must be controlled, and ammonia (NH3) or other additives must be added slowly in small portions to ensure that nickel (Ni), manganese (Mn) and cobalt (Co) can be co-precipitated together to form micron-sized nickel-manganese-cobalt hydroxide (NMC(OH)2) secondary particles. The co-precipitated (NMC(OH)2) secondary particles are usually agglomerates of nanometer-sized primary particles. Therefore, the final lithium NMC transition metal oxide (LiMeO2) prepared from the NMC(OH)2 precursor compound is also an agglomerate. These agglomerates are easily broken under high pressure during the electrode calendering step and coating onto the collector foil. Therefore, when these lithium NMC transition metal oxide materials are used as cathode active materials, a relatively low pressure must be used in the calendering step, and the electrode density of the produced cathode is further limited.

[0012] In the conventional preparation process of LiMeO2 active cathode material, precursor compounds such as lithium hydroxide (LiOH) and transition metal hydroxide (Me(OH)2) are mixed uniformly in solid form and stored in a thick Al2O3 crucible. Then, the crucible is placed in a furnace that is heated at a rate of 5-10°C / min until it reaches 900°C to 950°C and calcined for 10 to 20 hours. Since the precursor compound is heated at high temperature for a long time, adjacent particles are sintered together, so a grinding step is usually required after calcination. Therefore, particles of unwanted size need to be screened out after grinding, further reducing the overall yield. High temperature and long reaction time also lead to the gasification of lithium metal, so it is usually necessary to add up to 10% additional amount of lithium precursor compound during calcination to ensure that the final product has the correct lithium / transition metal ratio. In summary, the process time for this multi-stage batch production process will require up to one week, so it is very labor-intensive and consumes a lot of energy. Batch processing also increases the chance of introducing impurities, has poor batch-to-batch quality consistency, and has low overall yield.

[0013] Therefore, improved processes and systems are needed to prepare high quality, structured active materials for battery cells. Summary of the invention

[0014] The present invention generally relates to a system having a power injection module connected to a dispersion chamber for producing a product material from a liquid mixture. More specifically, the present invention relates to a method and system for producing material particles (e.g., active electrode materials, etc.) having a desired crystal structure, size, and morphology.

[0015] In one embodiment, a processing system having a power jet module is provided, the power jet module is connected to a dispersion chamber for producing a product material from a liquid mixture, and includes a matrix containing one or more power jet modules, the matrix is ​​suitable for spraying the liquid mixture into one or more droplet streams and forcing the one or more droplet streams into the processing system, wherein each power jet module includes a power jet. The process also includes a dispersion chamber, the dispersion chamber is suitable for being connected to the one or more power jet modules, and receiving the one or more droplet streams dispersed therein in the dispersion chamber with one or more gas streams to disperse into a gas-liquid mixture. In one embodiment, the process also includes a reaction chamber connected to the dispersion chamber and suitable for processing the gas-liquid mixture into a product material.

[0016] In one embodiment, the dispersion chamber comprises one or more openings, and the power ejector of each power ejector module is adapted to be movably coupled to the opening of the dispersion chamber, wherein the first actuator is controlled by the electronic control center and adapted to move the power ejector to be connected to the opening on the dispersion chamber accordingly.

[0017] In one embodiment, the first actuator is controlled by the electronic control center and is adapted to move the power jet to be connected to the opening on the dispersion chamber accordingly. In addition, the power jet of each power jet module is moved by the first actuator of the power jet module to be positioned in a first position connected to the opening of the dispersion chamber. In one embodiment, each power jet module also includes a sealing assembly to seal each power jet module with the opening of the dispersion chamber in a first position and the door, so that the power jet is adapted to be positioned in a closed position and in an open position by the second actuator. In addition, the power jet of each power jet module is moved by the first actuator of the power jet module to be positioned in a second position away from the opening of the dispersion chamber.

[0018] In one embodiment, the power nozzle of the processing system also includes a matrix of one or more nozzle holes, each hole is suitable for spraying the liquid mixture into one or more droplet streams. In one embodiment, the power injection module of the processing system also includes a cleaning assembly. The cleaning assembly of each power injection module also includes a removable cleaning scraper assembly and a removable suction assembly. In one embodiment, the processing system also includes a buffer chamber, the buffer chamber has a gas distributor, and the gas distributor has one or more channels for forming one or more carrier gases into one or more gas streams. The processing system also includes an electronic control center.

[0019] In an alternative embodiment, a processing system having a power jet module connected to a dispersion chamber to produce a product material from a liquid mixture is provided, the processing system comprising a matrix of one or more power jet modules adapted to jet the liquid mixture into one or more droplet streams, wherein each power jet module comprises a power jet and a support frame for supporting the movement of the power jet, and a dispersion chamber connected to the one or more power jet modules, adapted to receive and receive the one or more droplet streams, and wherein the power jet of each power jet module is adapted to be positioned at a first position to be connected to an opening of the dispersion chamber, and at a second position away from the opening of the dispersion chamber. In this embodiment, the processing system also comprises a reaction chamber connected to the dispersion chamber and adapted to process the one or more droplet streams into the product material.

[0020] In yet another embodiment, a method for producing a product material from a liquid mixture using a power jet module coupled to a dispersion chamber is provided, the method comprising moving each of the one or more power jet modules in a first direction to position it in a first position and connected to an opening of a dispersion chamber of a processing system, matching each of the one or more power jet modules with each of the one or more openings on the dispersion chamber, and opening one or more doors of the one or more power jet modules. The method also includes processing one or more droplet streams in a reaction chamber of the processing system, closing one or more doors of the power jet module, and moving each of the one or more power jet modules in a second direction to position it in a second position and away from the opening of the dispersion chamber. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to understand the above-mentioned features of the present invention in more detail, the present invention can be described in more detail by reference to embodiments, which are briefly summarized above, some of which are shown in the accompanying drawings. However, it should be noted that the accompanying drawings only show typical embodiments of the present invention and should not be considered as limiting the scope of the present invention, as the present invention may allow other equivalent embodiments.

[0022] Figure 1A is a perspective view of one embodiment of a system having a kinetic jetting module coupled to a dispersion chamber for producing a product material from a liquid mixture.

[0023] Figure 1B is a cross-sectional view of one embodiment of a system having a motive jetting module coupled to a dispersion chamber for producing a product material from a liquid mixture.

[0024] Figure 2A is a cross-sectional view of an apparatus that may be used in a system having a motive jetting module coupled to a dispersion chamber for producing a product material from a liquid mixture.

[0025] Figure 2B yes Figure 2A A perspective view of a dispersion chamber of the apparatus described in which may be used in a system in which a kinetic injection module is connected to the dispersion chamber to produce a product material from a liquid mixture.

[0026] Figure 2C is a cross-sectional view of a dispersion chamber of the apparatus that may be used in a system having a motive jetting module connected to the dispersion chamber for producing a product material from a liquid mixture.

[0027] Figure 2D The angle between the gas flow and the droplet flow within the dispersion chamber is shown according to one embodiment of the present invention.

[0028] Figure 2E is a perspective view of a motive ejector and holes therein according to one embodiment of the present invention.

[0029] Figure 3 An exemplary motive jetting module configured in a dispersion chamber of a processing system according to another embodiment of the present invention is shown in perspective view.

[0030] Figure 4 An exemplary motive jetting module configured in a dispersion chamber of a processing system according to another embodiment of the present invention is shown in perspective view.

[0031] Figure 5 An exemplary motive jetting module configured in a dispersion chamber of a processing system according to another embodiment of the present invention is shown in perspective view.

[0032] Figure 6 An exemplary motive jetting module configured in a dispersion chamber of a processing system according to another embodiment of the present invention is shown in perspective view.

[0033] Fig. 7A is a cross-sectional view of an exemplary motive injection module coupled to a dispersion chamber when a door of the motive injection module is in an "open" position and a liquid mixture is injected into the dispersion chamber.

[0034] Figure 7B is a cross-sectional view of an exemplary motive injection module coupled to a dispersion chamber when the motive injection module is in a “park” position and a door of the motive injection module is closed.

[0035] Figure 7C is a cross-sectional view of an exemplary motive injection module coupled to a dispersion chamber when the motive injection module is in a “service” position and a door of the motive injection module is closed.

[0036] Figure 8 The steps of a method performed on a system coupling a motive jetting module to a dispersion chamber are shown.

[0037] Fig. 9 Steps of a method performed on a system having a motive jetting module coupled to a dispersion chamber for producing a product material from a liquid mixture are shown. DETAILED DESCRIPTION

[0038] The present invention generally provides a processing system having a power injection module connected to a dispersion chamber and a method thereof. The processing system includes a matrix of one or more injection modules, a dispersion chamber and a reaction chamber. The processing system can be used to perform a continuous process to manufacture granular materials, saving material manufacturing time and energy, and solving the problems of high manufacturing cost, low yield, poor quality consistency, low electrode density, and low energy density in traditional manufacturing processes for active materials.

[0039] In one aspect, a liquid mixture (which may be a metal-containing liquid mixture) can be rapidly injected into a droplet stream by a power injection of a power injection module and then dispersed into a dispersion chamber. The droplet stream is continuously mixed with a gas to form a gas-liquid mixture, which is then transported into a reaction chamber and reacted in the reaction chamber. Alternatively, the droplet stream is transported into a reaction chamber and reacted in the reaction chamber.

[0040] On the other hand, the air flow or gas flow is used as a gas source for forming a gas-liquid mixture with the liquid mixture, and as a carrier gas chamber for transporting the gas-liquid mixture from the dispersion chamber to the reaction chamber. If the gas is heated before entering the dispersion chamber, the gas can also be used as an energy source for the gas-liquid mixture to react in the reaction chamber.

[0041] The reaction product from the reaction chamber is conveyed out of the reaction chamber. The reaction product typically comprises a fine powder of an oxidized form of solid material particles or a liquid mixture composition (e.g., a fine powder of a metal oxide material, such as a mixed metal oxide material) having a desired crystal structure, particle size, and morphology. Thus, high quality and consistent active particulate material can be obtained with less time, labor, and supervision than materials prepared from conventional manufacturing processes.

[0042] System having a kinetic jetting module coupled to a dispersion chamber for producing a product material from a liquid mixture

[0043] Figure 1A is a perspective view of one embodiment of a processing system 100 for producing particulate material. The exemplary embodiment of the processing system 100 includes a system inlet 102 for delivering one or more gases through a gas pipeline 106 and a system outlet 104 for delivering the particulate material outside the processing system. The one or more gases can be selected from gas sources such as air, oxygen, carbon dioxide, nitrogen, hydrogen, inert gases, noble gases, and combinations thereof.

[0044] The processing system 100 includes a system inlet 102 for delivering one or more gases into the processing system, a buffer chamber 230 connected to the system inlet 102, a dispersion chamber 220 connected to the buffer chamber 230, a reaction chamber 210 connected to the dispersion chamber 220, and a system outlet 104 connected to the reaction chamber 210. In one embodiment, the processing system 100 further includes an array of one or more power injection modules 240A, 240B, 240C, 240D, etc. for injection, for injecting the liquid mixture into one or more droplet streams and forcing the one or more droplet streams into the processing system 100. The processing system also includes a reaction chamber for processing the one or more droplet streams and the one or more gases into particulate matter.

[0045] The liquid mixture is prepared from two or more precursor compounds and then converted into droplets, each droplet of which will evenly distribute the two or more precursors together. The water content of the liquid mixture is then removed by passing the droplets through the dispersion chamber 220, and the mist is carried in the dispersion chamber for an appropriate residence time using an air flow. It is also expected that the concentration of the precursor compounds in the liquid mixture and the droplet size of the mist of the liquid mixture can be adjusted to control the chemical composition, particle size, and particle size distribution of the final product particles of the battery material.

[0046] In another embodiment, if Figure 1A As shown, the processing system 100 further includes at least one buffer chamber (eg, buffer chamber 230) configured to be connected to the system inlet 102 for delivering one or more gases from one or more gas sources into a plurality of uniform gas flows.

[0047] In another embodiment, the processing system 100 also includes a dispersion chamber 220 and power injection modules 240A, 240B and 240C, which are used to prepare the precursor liquid mixture into the required size and transport the required precursor liquid mixture into the processing system. The power injection module can be attached to a part of the dispersion chamber, and the liquid mixture is sprayed by air pressure and directly converted into a mist containing small-sized droplets inside the dispersion chamber. Alternatively, the mist can be generated outside the dispersion chamber and transported to the dispersion chamber. Suitable droplet size can be adjusted according to the selection of the power injection module used, the liquid mixture compound, the temperature of the dispersion chamber, the flow rate of the gas, and the residence time in the dispersion chamber. For example, a mist with a droplet size between one tenth of a micron and one millimeter is generated in the dispersion chamber.

[0048] In one example, the power jet module 240A is coupled to a portion of the dispersion chamber 220 to directly generate a mist of the liquid mixture (e.g., a large collection of small-sized droplets) within the dispersion chamber. Typically, the power jet module 240A is capable of generating a mist of droplets of a single size. In one embodiment, the dispersion chamber 220 is coupled to one or more power jet modules 240A, 240B, and 240C to receive a plurality of uniform gas streams from the buffer chamber and disperse the plurality of uniform gas streams into one or more droplet streams ejected from a matrix comprising the one or more power jet modules 240A, 240B, and 240C.

[0049] In another example, the dispersion chamber 220 is then connected to the reaction chamber 210 to process the one or more droplet streams and the one or more gases into particulate material. In addition, the reaction chamber 210 is connected to the system outlet 104 for transporting the particulate material out of the processing system.

[0050] Figure 1Bis a cross-sectional view of an exemplary processing system 100 that can be used to perform a rapid, simple, continuous and low-cost manufacturing process to produce particulate materials. In one embodiment, the processing system 100 also includes a gas distributor 232 attached to the chamber wall 238 of the buffer chamber 230, the channel of the distributor 232 is used to deliver one or more gases F1 into multiple uniform gas flows F2 inside the processing system, the dispersion chamber 220 and one or more power injection modules 240A and 240B attached to the chamber wall 228 of the dispersion chamber 220.

[0051] In one embodiment, the one or more gases F1 delivered to the buffer chamber 230 are pressurized downward, pass through the channel 234 of the gas distributor 232 at a certain speed to become multiple uniform airflows F2 and flow out of the channel 234 into the dispersion chamber 220. In one embodiment, the one or more gases F1 can be pumped through an air filter to remove any particles, droplets or pollutants, and the flow rate of the gas can be adjusted by a valve or other means. In one embodiment, the flow rate of the multiple uniform airflows F2 coming out of the channel 234 will be higher than the flow rate of the one or more gases F1. In addition, the directions of the multiple uniform airflows F2 will be collected and unified.

[0052] In one embodiment, the power injection module 240A includes a power injector 242A for injecting the liquid mixture supplied to the power injection module 240A into one or more droplet streams. The power injection module 240A also includes a support frame 244A for supporting the power injection module 240A, a module actuator 246A attached to the inner side of the support frame 244A for actuating and forcing one or more droplet streams FA injected from the inner power injector attached to the support frame 244A to be injected into the dispersion chamber 220, and a connector 245A connecting the module actuator 246A and the power injector 242A. In addition, the power injection module 240B includes a power injector 242B for injecting the liquid mixture supplied to the power injection module 240B into one or more droplet streams. The power jet module 240B further includes: a support frame 244B for supporting the power jet module 240B; a module actuator 246B, which is attached to the inner side of the support frame 244B and is used to actuate and force one or more droplet streams FA ejected from the inner power ejector attached to the support frame 244A to be ejected into the dispersion chamber 220, and a connector 245B, which connects the module actuator 246B and the power ejector 242B.

[0053] In one embodiment, the droplet stream FA injected into the dispersion chamber 220 is dispersed with a plurality of uniform airflows F2 at a dispersion angle αA, and forms a gas-liquid mixture F3 including a plurality of uniform airflows F2 and the droplet stream FA. In addition, the droplet stream FB injected into the dispersion chamber 220 is dispersed with a plurality of uniform airflows F2 at a dispersion angle αB, and forms a gas-liquid mixture F3 including a plurality of uniform airflows F2 and the droplet stream FB. In one embodiment, the dispersion chamber maintains itself at a first temperature.

[0054] In another embodiment, one or more gases are heated to a drying temperature to mix with and remove moisture from the liquid droplet stream. It is designed to obtain spherical solid particles from a well-mixed liquid mixture of two or more liquid mixtures after drying the mist of the liquid mixture. In contrast, conventional solid-state manufacturing processes involve mixing or grinding a solid mixture of liquid mixture compounds, resulting in an uneven mixing of the liquid mixture.

[0055] For example, the one or more gases can be, inter alia, air, oxygen, carbon dioxide, nitrogen, hydrogen, an inert gas, a rare gas and a combination thereof. For example, heated air can be used as a cheap gas source and energy source for drying the droplet stream. The selection of one or more gases can be a gas that is fully mixed with the droplet stream of the precursor and dries the mist without reacting with the precursor. In some cases, depending on the drying temperature and the chemical composition of the precursor, the chemical substances in the droplet stream may react to a certain extent with the one or more gases and / or with each other during the drying process. In addition, the residence time of the droplet stream of the fully mixed precursor compound in the dispersion chamber is adjustable, and can be, for example, from one second to one hour, and depending on the flow rate of the one or more gases, the length of the path that the droplet stream must flow in the dispersion chamber.

[0056] In one embodiment, the processing system 100 further includes a reaction chamber 210 for receiving the gas-liquid mixture F3 and performing the desired reaction of the gas-liquid mixture F3 to the final reaction product F4 at a second temperature and a reaction time. Finally, the final reaction product F4, which can be a product particle, can be transported outside the system 100 through the system outlet 104 to further analyze their properties (e.g., specific capacity, power performance, particle charging cycle performance, etc.), particle size, morphology, crystal structure, etc. used as a particle material.

[0057] Alternatively, in one embodiment, the reaction chamber 210 is a circulating fluidized bed reactor for receiving the gas-liquid mixture F3 from the dispersion chamber and mixing it with the preheated second gas stream to form the final reaction product F4 within the internal volume of the reaction chamber 210. The final reaction product F4 is heated by the thermal energy of the preheated second gas, and the complete reaction is enhanced by causing the final reaction product F4 to flow continuously from the reaction chamber 210 to a gas-solid separator connected to the reaction chamber 210. The gas-solid separator is used to remove byproducts (and / or a portion of the reaction products) from the system 100 through the separator outlet and recycle the solid particles back to the reaction chamber 210 through the separator outlet. Product particles having a desired size, crystal structure and morphology are collected and discharged from the gas-solid separator through the separator outlet.

[0058] Optionally, in another embodiment, the reaction chamber 210 is a bubbling fluidized bed reactor. The preheated second gas stream from the gas pipeline is transported into the reaction chamber 210 and passes through the porous medium to mix with the gas-liquid mixture F3 transported from the dispersion chamber 220 and produce a bubbling gaseous fluid-solid mixture therein, in the internal volume of the reaction chamber. The bubbling gas-solid mixture is heated by the thermal energy of the preheated second gas, and the complete reaction is enhanced by the bubbling flow in the reaction chamber 210. After the reaction is completed, the gaseous by-products are removed from the reaction chamber 210 through the reactor outlet. The final reaction product F4 with the desired crystal structure, morphology and size is collected and transported out of the reaction chamber 210 via the system outlet 104.

[0059] Optionally, in another embodiment, the reaction chamber 210 is an annular fluidized bed reactor. The preheated second gas stream from the gas pipeline is transported to the reaction chamber 210, and is also diverted to another gas stream, such as a gas stream, to promote the heated gas to be fully mixed with the gas-liquid mixture F3 transported from the dispersion chamber 220, and to produce a uniformly mixed gas-solid mixture in the internal volume of the reactor reaction chamber. After the reaction is completed, the gaseous by-products are removed from the reaction chamber 210 through the reactor outlet. Product particles with desired crystal structure, morphology and size are collected and transported to the outside of the reaction chamber 210 via the system outlet 104.

[0060] Optionally, in another embodiment, the reaction chamber 210 is a flash fluidized bed reactor. The reaction chamber 210 receives the gas-liquid mixture F3 from the dispersion chamber 220 and mixes it with the preheated gas flow from the gas pipeline to form a gas-solid mixture. The gas-solid mixture passes through a tubular reactor body connected to the reaction chamber 210. The gas-solid mixture must pass through a longer internal path, which promotes the use of the thermal energy of the heated gas to complete the reaction. The gaseous by-products are then removed from the reaction chamber 210 through the reactor outlet, and product particles with the desired crystal structure, morphology and size are collected and discharged from the reaction chamber 210 through the system outlet 104. Additional gas pipelines can be used to deliver heated or cooled air or gas to the reaction chamber 210.

[0061] In one embodiment, the final reaction product F4 includes metal oxide materials, doped metal oxide materials, inorganic metal salts, etc. Exemplary metal oxide materials include, but are not limited to, titanium oxide (TiO2). x O y , such as Ti2O5), chromium oxide (Cr x O y , such as Cr2O7), tin oxide (Sn x O y , such as SnO2, SnO, SnSiO3, etc.), copper oxide (Cu x O y , such as CuO, Cu2O, etc.), aluminum oxide (Al x O y , such as Al2O3), manganese oxide (Mn x O y ), iron oxide (Fe x O y , such as Fe2O3, etc.). For mixed metal oxide materials, it is desirable to control the composition of the final reaction product material by the ratio of the liquid mixture compound added to the liquid mixture added to the processing system 100. In one embodiment, a metal (Me x Me' y O z Examples include lithium transition metal oxides (LiMeO2), lithium titanium oxides (e.g. Li4Ti5O 12 ), lithium cobalt oxide (such as LiCoO2), lithium manganese oxide (such as LiMn2O4), lithium nickel oxide (such as LiNiO2), lithium iron phosphate (such as LiFePO4), lithium cobalt phosphate (such as LiCoPO4), lithium manganese phosphate (such as LiMnPO4), nickel phosphate (such as LiNiPO4), sodium iron oxide (such as NaFe2O3), sodium iron phosphate (such as NaFeP2O7), among which.

[0062] In another embodiment, the final reaction product F4 includes a metal oxide having three or four intercalated metals. Exemplary metal oxide materials include, but are not limited to, lithium nickel cobalt oxide (e.g., Li x Ni y Co z O2), lithium nickel manganese oxide (e.g., Li x Ni y Mn z O2, Li x Ni y Mn z O4, etc.), lithium nickel manganese cobalt oxide (e.g., Li a Ni b Mn c Co d O e ). Layered structure; and / or LiNi x Mn y Co z O2, a NMC oxide material with x+y+z=1, such as LiNi 0.33 Mn 0.33 Co 0.33 O2, LiNi 0.6 Mn 0.2 Co 0.2 O2, LiNi 0.5 Mn 0.3 Co 0.2 O2, LiNi 0.0.4 Mn 0.4 Co 0.2 O2, LiNi 0.7 Mn 0.15 Co 0.15 O2, LiNi 0.8 Mn 0.1 Co 0.1 O2, etc.; and / or mixed metal oxides doped with metals, etc. Other examples include lithium cobalt aluminum oxide (e.g., Li x Co y Al z O n ), lithium nickel cobalt aluminum oxide (such as Li x Ni y Co z Al a O b ), sodium iron manganese oxide (such as Na x Fe y Mn z O2) etc.; in another example, a mixture of mixed metal oxides and doped metals is obtained; for example, Li a (Ni xMn y Co z )MeOb (where Me = doping metal of Al, Mg, Fe, Ti, Cr, Zr or C), Li a (Ni x Mn y Co z )MeO b Fc (wherein Me = doping metal of Al, Mg, Fe, Ti, Cr, Zr or C), wherein.

[0063] Other metal oxide materials, including one or more lithium (Li), nickel (Ni), manganese (Mn), cobalt (Co), aluminum (Al), titanium (Ti), sodium (Na), potassium (K), (Rb), vanadium (V), cesium (Cs), copper (Cu), magnesium (Mg), iron (Fe), etc. can also be obtained. In addition, the metal oxide material can present a crystal structure of a metal in the shape of a layer, spinel, olivine, etc. In addition, the final reaction product F4 exists in the form of a desired solid powder. The particle size of the solid powder is between 10nm and 100μm.

[0064] In one embodiment, the processing system 100 is connected to an electronic control unit 300, which includes a CPU 340 for automatically controlling the processing system 100. The electronic control unit 300 adjusts various processing parameters (e.g., flow rate, mixing ratio, temperature, residence time, etc.). For example, the flow rate of the liquid mixture entering the system 100 can be adjusted. As another example, the droplet size and generation rate of one or more droplet streams generated by the power injection module can be adjusted. In addition, the flow rate and temperature of various gases flowing in the gas pipeline 102 can be controlled by the electronic control unit 300. In addition, the electronic control unit 300 is suitable for controlling the temperature and residence time of various gas-liquid mixtures, as well as solid particles, at desired levels at various locations.

[0065] Optionally, in one embodiment, the processing system 100 further includes a first separator, which is connected to the dispersion chamber 230 and is suitable for collecting and separating the gas-liquid mixture F3 from the dispersion chamber into solid particles of the first type and waste. Optionally, the first separator is connected to a drying chamber, which is connected to the dispersion chamber 230 and is suitable for collecting and drying the gas-liquid mixture F3 from the dispersion chamber into gas-solid particles for transportation and separation into solid particles of the first type and waste products in the first separator. In one embodiment, the first separator further includes a first separator outlet connected to the reaction chamber 210 and suitable for transporting the solid particles of the first type into the reaction chamber 210, and a second separator outlet suitable for transporting the waste out of the first separator.

[0066] In one embodiment, the final reaction product F4 is collected and cooled through one or more separators, cooling fluid lines, and / or heat exchangers, and once cooled, exits the system 100. The final reaction product F4 may include a mixed liquid in an oxidized form, e.g., an oxide material, suitable for packaging into a battery cell. Additional pumps may also be installed to achieve the desired pressure gradient.

[0067] Figure 2A 1 is a cross-sectional view of a buffer chamber 230 for performing a process for preparing a granular material according to an embodiment of the present invention. Referring again to FIG. 1 , Figure 2A The buffer chamber 230 in is cut off by the dashed line BB′. In one embodiment, the buffer chamber 230 includes a cylinder gas distributor 232 for delivering one or more gases from the system inlet into a plurality of uniform gases, which are enclosed within the inner side of the chamber wall 238 of the buffer chamber 230 and are located at the bottom of the buffer chamber 230, and a channel 234 of the gas distributor 232 for passing the one or more gases in a uniform direction and flow rate.

[0068] Figure 2B 2 is a perspective view of a buffer chamber 230 including a cylinder gas distributor 232 and a channel 234 of the gas distributor 232 enclosed within a chamber wall 238 of the buffer chamber 230 .

[0069] Figure 2C FIG. 1 is a cross-sectional view of a dispersion chamber 220 configured in a processing system 100 according to an embodiment of the present invention. Referring again to FIG. 1 , Figure 1B The dispersion chamber 220 in FIG. 2 is cut off by a dotted line AA′. The dispersion chamber 220 is surrounded by a chamber wall 228 .

[0070] In one embodiment, a matrix of one or more power injection modules, namely power injection module 240A, power injection module 240B, power injection module 240C and power injection module 240D, is positioned in one or more openings 222A, 222B, 222C of chamber wall 228 of dispersion chamber 220. In one embodiment, power injection modules 240A-240D may be arranged in a plurality of positions. Figure 2C One arrangement shown is attached to the chamber wall 228 of the dispersion chamber 220. The arrangement may be that each of the four motive ejectors are arranged on the chamber wall 228 at the same level of the chamber wall 228 at a uniform distance from each other.

[0071] In one embodiment, the power jet module 240A includes a power jet 242A for spraying the liquid mixture supplied to the power jet module 240A into one or more droplet streams. The power jet module 240A also includes a support frame 244A for supporting the power jet module 240A, a module actuator 246A attached to the inner side of the support frame 244A, for actuating and forcing one or more droplet streams FA sprayed from the inner power jet attached to the support frame 244A to be sprayed into the dispersion chamber 220, and a connector 245A, which connects the module actuator 246A and the power jet 242A. Similarly, the power jet module 240B includes a power jet 242B, a support frame 244B, a module actuator 246B and a connector 245B. Similarly, the power jet module 240C includes a power jet 242C, a support frame 244C, a module actuator 246C and a connector 245C. Furthermore, the power jet module 240D includes a power jet 242D, a support frame 244D, a module actuator 246D and a connector 245D.

[0072] In one embodiment, the motive ejectors 242A-242D are positioned near the top of a vertically disposed dispersion chamber 220 (eg, a dome-shaped dispersion chamber, etc.) to direct the droplet stream F A-D The power injectors 242A-242D may be located near the bottom of the vertically positioned dispersion chamber 220 and may be capable of injecting the droplet stream upwardly into the dispersion chamber to increase the residence time of the stream generated therein. In another embodiment, when the dispersion chamber 220 is horizontally positioned (e.g., a tube dispersion chamber, etc.), and the power injectors 242A-242D are located near one end of the dispersion chamber 220, so that the mist stream is transported from one end of the dispersion chamber 220 to the other end, the mist stream may pass through the path within the dispersion chamber 220 over the length of its residence time.

[0073] In addition to the liquid mixture flow, the dispersion chamber 220 is also filled with a gas flow. The gas distributor 232 is connected to the end of the buffer chamber and is suitable for flowing a plurality of uniform gases F2 into the dispersion chamber 220. The uniform gas flow F2 can be delivered into the dispersion chamber 220 at the same time as the droplet flow is formed inside the dispersion liquid, so that the droplet flow passes through the dispersion chamber 220, and can remove moisture from the mist or not, and form a gas-liquid mixture with a direction F3, which contains the liquid mixture. Moreover, the plurality of uniform gas flows F2 can be delivered to the dispersion chamber 220 before the mist is formed to fill and preheat the internal volume of the dispersion chamber 220 to a first temperature before the droplet flow is generated inside the dispersion chamber 220.

[0074] In one example, the gas distributor 232 is connected to the end of the buffer chamber 230, which is connected to the top of the dispersion chamber 310 to deliver the plurality of uniform gases F2 into the dispersion chamber 220 to mix with the droplet stream generated by the power injection module attached to the chamber wall 228 of the dispersion chamber 220. In one embodiment, the plurality of uniform gases F2 are preheated to a temperature between 70° C. and 600° C. to mix with the droplet stream and remove moisture from the droplet stream. In another embodiment, the plurality of uniform gases F2 are not preheated, but are used to ensure that the gas-liquid mixture formed in the dispersion chamber 220 is uniformly mixed with the gas.

[0075] Figure 2D 1 shows dispersion angles of a plurality of uniform gas F2 and droplet flows FA within dispersion chamber 220 configured in processing system 100 of FIG. 1 according to one embodiment of the present invention.

[0076] Figure 2D It shows that in the dispersion chamber 220, the droplet flow FA is dispersed into the multiple uniform gases F2 at a dispersion angle αA. The dispersion angle αA is measured based on the angle between the direction of the droplet flow FA and the multiple uniform gases F2 on the vertical Z axis, and in a 3D stereogram set on the XYZ axis.

[0077] In one embodiment, the droplet stream of the liquid mixture (e.g., droplet stream FA) and the gas stream (e.g., multiple unified gases F2) can meet each other at an angle of 0 to 180 degrees inside the dispersion. In addition, the droplet stream FA and the air stream in the gas stream F2 can flow in a straight line, spiral, winding and / or other manners.

[0078] In one embodiment, the droplet stream FA and the multiple unified gases F2 are configured at an angle αA (0≤αA≤180o) and can be merged into a mixed flow (e.g., parallel flow) within the dispersion chamber. In addition, the droplet stream FA and the multiple unified gases F2 can flow at various angles pointing to each other and / or to the periphery of the chamber body within the dispersion chamber 220 to promote the formation of spirals, entanglements and / or other airflows. In one embodiment, the droplet stream and the airflow are configured at an angle α of less than 90 degrees and can be merged into a mixed flow within the dispersion chamber. In another embodiment, the droplet stream FA and the airflow F2 are configured at an angle α of 90 degrees and can be merged into a mixed flow within the dispersion chamber. In addition, the droplet stream FA and the airflow F2 can flow at various angles pointing to each other and / or to the periphery of the chamber body to promote the formation of spirals, entanglements and / or other airflows within the dispersion chamber 220.

[0079] For example, the flow of gas and the flow of droplet streams flowing in the dispersion chamber can be configured as co-flow. The advantages of co-flow are shorter residence time, lower particle drying temperature and higher particle separation efficiency. In another embodiment, the flow of multiple uniform gases dispersed in the mixing chamber and the flow of droplet streams can be configured to flow as counter-flow. The advantages of counter-flow are longer residence time and higher particle drying temperature.

[0080] In another embodiment, the droplet stream FA and the gas stream F2 are configured at an angle α of 180 degrees and flow as countercurrents. In an alternative embodiment, the dispersion chamber 220 can be placed horizontally. Similarly, the droplet stream FA and the gas stream F2 can be configured at an angle α between 0 and 180 degrees. Referring again to FIG. 1 , once the droplet stream of the liquid mixture forms a gas-liquid mixture with the gas, the gas-liquid mixture is transported to the reaction chamber 210 through the dispersion chamber 220.

[0081] The motive ejector 242A is connected to the liquid source 720 to store a desired amount of the liquid mixture compound, and the electronic control unit 300 is used to direct and control the delivery of the liquid mixture compound from the liquid source 720 to the motive ejector 242A.

[0082] In another configuration, the liquid mixture within the liquid source 720 can be pumped from the liquid source 720 to the motive ejector 242A by a pump. The pumping of the liquid mixture by the pump can be configured, for example, to be continuously configured (e.g., regulated by a metering valve or other device) at a desired delivery rate to achieve good processing throughput of the processing system 100. In another configuration, the motive ejector 242A is located outside the dispersion chamber 220, and the flow generated thereby is delivered to the dispersion chamber 220 via the chamber inlet.

[0083] In one embodiment, the power ejector 242A is a rectangular parallelepiped structure having six rectangular faces at right angles to each other. In addition, the power ejector 242A includes a nozzle matrix 480A on one side of the power ejector 242A. In one embodiment, the nozzle matrix 480A is on the side of the power ejector 242A, has a bottom width shorter than the side length, and is composed of 3×10 uniformly placed rectangular holes 402A. In another embodiment, the nozzle matrix 480A is composed of another pattern of holes.

[0084] In another embodiment, the power ejector has a different shape and structure, such as having a cylindrical structure with straight parallel sides and a circular or elliptical cross-section. In addition, the power ejector includes a nozzle matrix on one straight parallel side of the power ejector. In one embodiment, the nozzle matrix consists of a single orifice.

[0085] Figure 3An example of a power jet module configured in a dispersion chamber of a processing system is shown in perspective view. In one embodiment, a power jet module 240A for jetting a liquid mixture into one or more droplet streams and forcing the one or more streams into the processing system includes a power jet 242A for jetting the liquid mixture supplied to the power jet module 240A into one or more droplets. The power jet module 240A also includes: a support frame 244A for supporting the movement of the power jet 242A; a first module actuator 246A for moving the power jet to be correspondingly connected to an opening on the dispersion chamber; and a connector 245A, which connects the first module actuator 246A and the power jet 242A. The power jet module also includes a sealing assembly 249A, a door 247A, a second module actuator 248A and a third module actuator 250A.

[0086] Likewise Figure 3 As shown, the dispersion chamber 220 includes one or more openings 222A, 222B, 222C, 222D, 222E and 222F, which are located on the wall of the dispersion chamber 220 and are suitable for connecting to and assembling a power jet of a power jet module with a nozzle matrix on one side. In one embodiment, the shape of the one or more openings and the arrangement of the one or more openings are Figure 3 , where one or more openings are rectangular in shape, with a base width shorter than a side length, and are placed adjacent to each other at a uniform distance on the same horizontal line of the chamber wall.

[0087] Likewise Figure 3 As shown, the dispersion chamber 220 is filled with a plurality of uniform gases F2 delivered from a buffer chamber of the processing chamber. In one embodiment, the plurality of uniform gas streams F2 are delivered simultaneously with the droplet stream formed inside the dispersion chamber by spraying from the spray module, and enter the dispersion chamber 220, so that the droplet stream passes through the dispersion chamber 220, and may or may not remove moisture from the mist, and form a gas-liquid mixture in a direction F3, which contains a liquid mixture. Moreover, the plurality of uniform gas streams F2 may be delivered to the dispersion chamber 220 before the droplet stream is formed, so as to fill and preheat the internal volume of the dispersion chamber 220 to a first temperature before the droplet stream is generated inside the dispersion chamber 220.

[0088] In one embodiment, one or more openings 222A-222F are located near the top of a vertically disposed dispersion chamber 220 (e.g., a dome-shaped dispersion chamber, etc.) to connect and assemble a power injection module for injecting a stream of droplets into the dispersion chamber 220 and passing vertically downward through the dispersion chamber. Alternatively, one or more openings 222A-222F can be located near the bottom of a vertically disposed dispersion chamber 220 and can be connected and mounted with a power injection module to inject the stream of droplets upward into the dispersion chamber to increase the residence time of the generated stream therein. In another embodiment, when the dispersion chamber 220 is horizontally disposed (e.g., a tubular dispersion chamber, etc.), and one or more openings 222A-222F are located near one end of the dispersion chamber 220 to fit and connect to a power injection module for transporting the injected stream of droplets from one end of the dispersion chamber 220 to the other end, the residence time of the droplets can be increased through a path within the dispersion chamber 220.

[0089] In addition, in one embodiment, the droplet stream injected into the dispersion chamber 220 is dispersed into the gas-liquid mixture F3 including the plurality of uniform air streams F2 and the droplet stream together with the plurality of uniform air streams F2. In one embodiment, the dispersion chamber maintains itself at a first temperature.

[0090] In one embodiment of the present invention, the directions of the multiple uniform airflows F2 delivered to the dispersion chamber are parallel to the chamber wall of the dispersion chamber 220. And the direction of the gas-liquid mixture F3 passing through the dispersion chamber 220 is also parallel to the chamber wall of the dispersion chamber 220. In another embodiment of the present invention, the directions of the multiple uniform airflows F2 delivered to the dispersion chamber 220 and the direction of the gas-liquid mixture F3 delivered through the dispersion chamber 220 are different.

[0091] Figure 4An example of one or more power jet modules configured in a dispersion chamber of a processing system is shown in perspective view. In one embodiment, a power jet module 440A for jetting a liquid mixture into one or more droplet streams and forcing the one or more streams into the processing system includes a power jet 442A for jetting a liquid mixture supplied to the power jet module 440A into one or more droplet streams. The power jet module 440A also includes: a support frame 444A for supporting the movement of the power jet 442A; a first module actuator 446A for moving the power jet to be connected to the opening on the dispersion chamber; and a connector 445A connecting the first module actuator 446A and the power jet 442A. The power jet module also includes a sealing assembly 449A, a door 447A, a second module actuator 448A and a third module actuator 450A. In the same embodiment, another power jet module 440G for jetting a liquid mixture into one or more droplet streams and forcing one or more streams into a treatment system includes a power jet 442G for jetting a liquid mixture supplied to the power jet module 440G into one or more droplet streams. The power jet module 440G also includes: a support frame 444G for supporting the movement of the power jet 442G; a first module actuator 446G for moving the power jet to be connected to the opening on the dispersion chamber accordingly; and a connector 445G connecting the first module actuator 446G and the power jet 442G. The power jet module also includes a sealing assembly 449G, a door 447G, a second module actuator 448G and a third module actuator 450G.

[0092] Likewise Figure 4 As shown, dispersion chamber 420 includes one or more openings 422A, 422B, 422C, 422D, 422E, 422F, 422G, 422H, 422I, 422J, 422K and 422L, which are located on the wall of dispersion chamber 420 and are suitable for connecting and assembling to the power jet of the power jet module and the power jet having the nozzle matrix. In one embodiment, the shape of one or more openings is as follows Figure 4 As shown, one or more of the openings are rectangular, with a base width shorter than a side length. Figure 4 , wherein the openings 422A-422F are positioned at a uniform distance from each other on the same horizontal line of the chamber wall in a first row, and the openings 422G-422L are positioned at a uniform distance from each other on the same horizontal line of the chamber wall in a second row different from the first row. In addition, each of the openings 422A-422L is not positioned on the same vertical line of the chamber wall to avoid overlapping each other.

[0093] Likewise Figure 4 As shown, the dispersion chamber 420 is filled with a plurality of uniform gases F2 delivered from the buffer chamber of the processing chamber. In one embodiment, the plurality of uniform gas streams F2 can be delivered into the dispersion chamber 220 at the same time as the droplet stream is formed inside the dispersion liquid, so that the droplet stream passes through the dispersion chamber 220, and can remove moisture from the mist, or can not remove moisture, and form a gas-liquid mixture in the direction of F3, which contains a liquid mixture and a plurality of uniform gases. Moreover, the plurality of uniform gas streams F2 can be delivered to the dispersion chamber 420 before the droplet stream is formed, so as to fill and preheat the internal volume of the dispersion chamber 420 to the first temperature before the droplet stream is generated inside the dispersion chamber 420.

[0094] In one embodiment, one or more openings 422A-422F are located near the top of a vertically disposed dispersion chamber 420 (e.g., a dome-shaped dispersion chamber, etc.) to connect and assemble a power injection module for injecting a stream of droplets into the dispersion chamber 420 and passing vertically downward through the dispersion chamber. In addition, in the same embodiment, one or more openings 422G-422L are located near the bottom of the dispersion chamber 420. In another embodiment, when the dispersion chamber 420 is horizontally disposed (e.g., a tubular dispersion chamber, etc.), and one or more openings 422A-422F are located near one end of the dispersion chamber 420 to assemble and connect to a power injection module, the power injection module delivers the injected stream of droplets from one end of the dispersion chamber 420 to the other end, and may stay on the path within the dispersion chamber 420 for a period of time. In addition, in the same embodiment, one or more openings 422G-422L are located near the other end of the dispersion chamber 420.

[0095] In addition, in one embodiment, the droplet stream injected into the dispersion chamber 420 is dispersed into the gas-liquid mixture F3 including the plurality of uniform air streams F2 and the droplet stream together with the plurality of uniform air streams F2. In one embodiment, the dispersion chamber maintains itself at a first temperature.

[0096] In one embodiment of the present invention, the directions of the multiple uniform airflows F2 delivered to the dispersion chamber are parallel to the chamber wall of the dispersion chamber 420. And the direction of the gas-liquid mixture F3 delivered through the dispersion chamber 420 is also parallel to the chamber wall of the dispersion chamber 420. In another embodiment of the present invention, the directions of the multiple uniform airflows F2 delivered to the dispersion chamber 420 and the direction of the gas-liquid mixture F3 delivered through the dispersion chamber 420 are different.

[0097] Figure 5An example of a power jet module configured in a dispersion chamber of a processing system is shown in perspective view. In one embodiment, a power jet module 540A for jetting a liquid mixture into one or more droplet streams and forcing one or more streams into a processing system includes a power jet 542A for jetting a liquid mixture supplied to the power jet module 540A into one or more droplet streams. The power jet module 540A also includes: a support frame 544A for supporting the movement of the power jet 542A; a first module actuator 546A for moving the power jet to be correspondingly connected to an opening on the dispersion chamber; and a connector 545A connecting the first module actuator 546A and the power jet 542A. The power jet module also includes a sealing assembly, a door, a second module actuator and a third module actuator.

[0098] Likewise Figure 5 As shown, the dispersion chamber 520 includes one or more openings 522A, 522B, 522C, 522D, 522E and 522F, which are located on the wall of the dispersion chamber 520 and are suitable for connecting to a power jet having a nozzle on one side of the power jet module, and the bottom width is longer than the side length. In one embodiment, Figure 5 The shape of one or more openings and the arrangement of one or more openings are shown, wherein the one or more openings are rectangular in shape with a base width longer than a side length and are placed adjacent to each other at uniform distances on the same vertical line of the chamber wall.

[0099] In one embodiment, one or more openings 522A-522F are located near the left end of the horizontally arranged dispersion chamber 520 (e.g., a tubular dispersion chamber, etc.) to connect and assemble a power injection module for injecting a droplet stream into the dispersion chamber 520 and passing through the dispersion chamber from one end to the other end. Alternatively, one or more openings 522A-522F can be located near the right end of the horizontally arranged dispersion chamber 520 and can connect and assemble a power injection module for injecting a droplet stream upward into the dispersion chamber to the length of the residence time of the stream generated therein. In one embodiment, the dispersion chamber maintains itself at a first temperature.

[0100] In one embodiment of the present invention, the directions of the multiple uniform airflows F2 delivered to the dispersion chamber are parallel to the chamber wall of the dispersion chamber 520. And the direction of the gas-liquid mixture F3 delivered through the dispersion chamber 520 is also parallel to the chamber wall of the dispersion chamber 520. In another embodiment of the present invention, the directions of the multiple uniform airflows F2 delivered to the dispersion chamber 520 and the direction of the gas-liquid mixture F3 delivered through the dispersion chamber 520 are different.

[0101] In one embodiment of the present invention, the directions of the multiple uniform airflows F2 delivered to the dispersion chamber are parallel to the chamber wall of the dispersion chamber 520. Also, the direction of the gas-liquid mixture F3 formed by dispersing the multiple uniform airflows F2 into the droplet stream from the power ejector through the dispersion chamber 520 is parallel to the chamber wall of the dispersion chamber 520.

[0102] Figure 6 An example of a power jet module configured in a dispersion chamber of a processing system is shown in perspective view. In one embodiment, a power jet module 640A for jetting a liquid mixture into one or more droplet streams and forcing one or more streams into a processing system includes a power jet 642A for jetting a liquid mixture supplied to the power jet module 640A into one or more droplet streams. The power jet module 640A also includes: a support frame 644A for supporting the movement of the power jet 642A; a first module actuator 646A for moving the power jet to be correspondingly connected to an opening on the dispersion chamber; and a connector connecting the first module actuator 646A and the power jet 642A. The power jet module also includes a sealing assembly, a door, a second module actuator and a third module actuator.

[0103] Likewise Figure 6 As shown, the dispersion chamber 620 includes one or more openings 622A, 622B, 622C, which are located on the wall of the dispersion chamber 620 and are suitable for connecting to and cooperating with the power nozzle of the power injection module, on one side of the power injector with the nozzle matrix. In one embodiment, Figure 6 The shape of the one or more openings and the arrangement of the one or more openings are shown, wherein the one or more openings are rectangular in shape with a base width longer than a side length and are placed adjacent to each other at a uniform distance on the same horizontal line of the chamber wall.

[0104] Likewise Figure 6 As shown, the dispersion chamber 620 is filled with a plurality of uniform gases F2 delivered from the buffer chamber of the processing chamber. In one embodiment, the plurality of uniform gas streams F2 can be delivered simultaneously with the droplet stream formed inside the dispersion chamber from the injector in the injection module, and enter the dispersion chamber 220, so that the droplet stream passes through the dispersion chamber 220, and can remove moisture from the mist, or not, and form a gas-liquid mixture with a direction F3, which contains a liquid mixture and a plurality of uniform gases. Moreover, the plurality of uniform gas streams F2 can be delivered to the dispersion chamber 220 before the droplet stream is formed, so as to fill and preheat the internal volume of the dispersion chamber 220 to a first temperature before the droplet stream is generated inside the dispersion chamber 220.

[0105] In one embodiment, one or more openings 622A-622C are located near the top of a vertically disposed dispersion chamber 620 (e.g., a dome-shaped dispersion chamber, etc.) to connect and fit a motive injection module for injecting a stream of droplets into the dispersion chamber 620 and vertically downward through the dispersion chamber. Alternatively, one or more openings 622A-622C may be located near the bottom of a vertically positioned dispersion chamber 620 and capable of connecting and fitting a motive injection module to inject a stream of droplets upward into the dispersion chamber to increase the residence time of the stream generated therein. In another embodiment, when the dispersion chamber 620 is horizontally disposed (e.g., a tubular dispersion chamber, etc.), and one or more openings 622A-622C are located near one end of the dispersion chamber 620 to fit and fit a motive injection module for transporting a stream of droplets from one end of the dispersion chamber 620 to the other end, which may pass through a path within the dispersion chamber 620 for the length of its residence time. In one embodiment, the dispersion chamber itself is maintained at a first temperature.

[0106] In one embodiment of the present invention, the directions of the plurality of uniform airflows F2 delivered into the dispersion chamber are parallel to the chamber wall of the dispersion chamber 620. Also, the direction of the gas-liquid mixture F3 formed by dispersing the plurality of uniform airflows F2 into droplet flows from the motive jet delivered through the dispersion chamber 620 is parallel to the chamber wall of the dispersion chamber 620.

[0107] Fig. 7A 2 is a front view of an exemplary power injection module adapted to be connected to a dispersion chamber, the power injection module being sealed with an opening on a chamber wall 228 of the dispersion chamber by a sealing assembly 249A of the power injection module 240A, and a power injector of the power injection module being located in a first position, the power injector 242A being located in a first position to be connected to the opening of the dispersion chamber. In one embodiment, the power injector 242A is capable of injecting one or more streams of droplets FA into the dispersion chamber at a first position under the control of an electronic control center.

[0108] Return to reference Figure 3 The power jet module further includes a support frame 244A, a first module actuator 246A for supporting the movement of the power jet 242A, a door 247A, a second module actuator 248A adapted to move the door 247A, and a third module actuator 250A. In one embodiment, the power jet module 240A further includes a cleaning assembly including a movable cleaning blade assembly 252A to be moved by the third module actuator 250A and a movable suction assembly 254A.

[0109] In one embodiment, the first modular actuator 246A is controlled by an electronic control center and is adapted to move the power ejector 242A by moving the connector 245A connected to the first modular actuator 246A and the power ejector 242A in the "H" direction, perpendicular to the chamber wall of the dispersion chamber. The connector 245A is moved by the first modular actuator 246A in the "H" direction toward the opening in the dispersion chamber, while the connector 245A moves the power ejector 242A in the "H" direction toward the opening in the dispersion chamber. Similarly, the connector 245A is moved by the first modular actuator 246A in the "H" direction away from the opening in the dispersion chamber, while the connector 245A moves the power ejector 242A in the "H" direction away from the opening in the dispersion chamber. When the power ejector 242A is moved to be correspondingly connected to the opening in the dispersion chamber, the first position of the power ejector 242A is reached.

[0110] In one embodiment, the second module actuator 248A is adapted to move the door 247A parallel to the chamber wall of the dispersion chamber in the direction of V1. When the door 247A is moved to the open position, the first position of the power ejector 242A is opened, in which the power ejector 242A passes through the door 247A to connect to the opening on the dispersion chamber.

[0111] Figure 7B 2 is a front view of an exemplary power jet module adapted to be coupled to a dispersion chamber, the power jet module being sealed by a sealing assembly 249A and a power jet module 240A, thereby sealing with an opening in a chamber wall 228 of the dispersion chamber. The power jet module is in a second position, in which a power jet 242A of the power jet module 240A is positioned away from the opening of the dispersion chamber. In one embodiment, under the control of the electronic control center, the power jet 242A does not eject one or more streams of droplets FA into the dispersion chamber in the second position.

[0112] Return to reference Figure 3The power jet module also includes a support frame 244A, a first module actuator 246A for supporting the movement of the power jet 242A, a door 247A, a second module actuator 248A suitable for moving the door 247A, and a third module actuator 250A. In one embodiment, the power jet module 240A also includes a cleaning assembly, which includes a movable cleaning blade assembly 252A to be moved by the third module actuator 250A and a movable suction assembly 254A. In one embodiment, the electronic control center includes a connection line 310, which connects and controls the second module actuator 248A to move along the direction of "V1", a connection line 320, which connects and controls the third module actuator 250A to move along the direction of "V1", and a connection line 330 connects and controls the first module actuator 248A to move along the direction of "H" and the CPU 340.

[0113] In one embodiment, the first module actuator 246A is controlled by an electronic control center and is adapted to move the power ejector by moving the connector 245A connecting the first module actuator 246A and the power ejector 242A in the "H" direction, back to Fig. 7A , which is perpendicular to the chamber wall of the dispersion chamber. When the power ejector 242A moves away from the opening on the dispersion chamber, the second position of the power ejector 242A is reached.

[0114] In one embodiment, returning to Fig. 7A , the second module actuator 248A is adapted to move the door 247A parallel to the chamber wall of the dispersion chamber along the direction of "V1". When the door 247A is moved to the closed position, the second position of the power ejector 242A is achieved, in which the power ejector 242A is blocked from passing through the door 247A.

[0115] Figure 7C 2 is a front view of an exemplary power injection module adapted to be coupled to a dispersion chamber, the power injection module being sealed to an opening in a chamber wall 228 of the dispersion chamber by a sealing assembly 249A of the power injection module 240A, and a cleaning assembly of the power injection module 240A for cleaning a power injector of the power injection module. Figure 7C As shown, the power jet module 240A further includes a cleaning assembly, which includes a movable cleaning blade assembly 252A moved along the direction of "V2" by a third module actuator 250A and a movable suction assembly 254A.

[0116] In one embodiment, the third module actuator 250A is adapted to move the cleaning blade assembly 252A in the direction V2, parallel to the face having the matrix of one or more nozzle holes of the power injector 242A, and utilize the cleaning blade assembly 252A to clean the surface with the cleaning blade assembly 252A when the power injector 252A is in the second position, in which the power injector 252A is positioned away from the opening in the chamber wall of the dispersion chamber, and the cleaning blade assembly 252A is connected to the surface having the array of one or more nozzle holes. In one embodiment, again referring to Figure 7B , the power ejector 242A moves in the second position and the door 247A moves in the closed position.

[0117] Method performed on a system having a kinetic jetting module coupled to a dispersion chamber for producing a product material from a liquid mixture

[0118] Figure 8 The steps of method 800 are shown as being performed on a system having a motive jetting module coupled to a dispersion chamber. Method 800 includes step 810, step 820, step 830, step 840, step 850, step 860, and step 870.

[0119] Step 810 of method 800 includes moving one or more power jet modules to a jetting position in a first direction. Step 820 of method 800 includes opening one or more doors on the one or more power jet modules. Step 830 of method 800 includes jetting the liquid mixture into one or more droplet streams into a dispersion chamber through one or more power jets of the one or more power jet modules.

[0120] In one embodiment, liquid mixture is formed by two or more precursors. Generally, liquid precursor compounds can be directly prepared into liquid mixtures of desired concentrations. Solid precursor compounds can be dissolved or dispersed in suitable solvents (e.g., water, alcohol, isopropanol or any other organic or inorganic solvents and combinations thereof) to form aqueous solutions, slurries, liquid mixtures of gels, aerosols or any other suitable liquid forms. For example, the molar ratio of two or more desired solid precursors can be prepared into liquid mixtures, such as by measuring and preparing into containers with an appropriate amount of two or more solid precursors and an appropriate amount of solvent. Depending on the solubility of the precursor in the solvent, pH, temperature and mechanical stirring and mixing can be adjusted to obtain a liquid mixture in which the precursor compound is completely dissolved and / or uniformly dispersed.

[0121] In one example, two or more metal-containing precursors are mixed into the liquid mixture to obtain a final reaction product of a mixed metal oxide material. Exemplary metal-containing precursors include, but are not limited to, metal salts, lithium-containing compounds, cobalt-containing compounds, manganese-containing compounds, nickel-containing compounds, lithium sulfate (Li2SO4), lithium nitrate (LiNO3), lithium carbonate (Li2CO3), lithium acetate (LiCH2COO), lithium hydroxide (LiOH), lithium formate (LiCHO2), lithium chloride (LiCl), cobalt sulfate (CoSO4), cobalt nitrate (Co(NO3)2), cobalt carbonate (CoCO3), cobalt acetate (Co(CH2COO)2), cobalt hydroxide (Co(OH)2), cobalt formate (Co(CHO2)2), cobalt chloride (CoCl2), manganese sulfate (MnSO4), manganese nitrate (Mn(NO3)2), manganese carbonate (MnCO3), manganese acetate (Mn(CH2COO)2), COO)2), manganese hydroxide (Mn(OH)2), manganese formate (Mn(CHO2)2), manganese chloride (MnCl2), nickel sulfate (NiSO4), nickel nitrate (Ni(NO3)2), nickel carbonate (NiCO3), nickel acetate (Ni(CH2COO)2), nickel hydroxide (Ni(OH)2), nickel formate (Ni(CHO2)2), nickel chloride (NiCl2), components containing aluminum (Al), compounds containing titanium (Ti), compounds containing sodium (Na), compounds containing potassium (K), compounds containing (Rb), compounds containing vanadium (V), compounds containing cesium (Cs), compounds containing chromium (Cr), compounds containing copper (Cu), compounds containing magnesium (Mg), compounds containing iron (Fe), and combinations thereof, etc.

[0122] Without wishing to be bound by theory, it is conceivable that, in order to prepare an oxide material having two or more different metals, all the desired metal elements are first mixed into a liquid mixture (e.g., into a solution, slurry, or gel mixture), using two or more metal-containing precursor compounds as the source of each metal element, so that two or more different metals can be uniformly mixed in a desired ratio. For example, in order to prepare a liquid mixture of an aqueous solution, slurry or gel, one or more metal salts with high water solubility can be used. For example, metal nitrates, metal sulfates, metal chlorides, metal acetates, formic acid metal salts can be used. Organic solvents, such as alcohols, isopropanol, etc., can be used to dissolve or disperse metal-containing precursors with low water solubility. In some cases, the pH value of the liquid mixture can be adjusted to increase the solubility of one or more precursor compounds. Optionally, chemical additives, gelling agents and surfactants such as ammonia, EDTA, etc. can be added to the liquid mixture to help dissolve or disperse the precursor compound in a selected solvent.

[0123] In one embodiment, the power jet module is selected from a group of a nozzle, a sprayer, an atomizer or any other mist generator. The power jet module uses air pressure to spray the liquid mixture and convert it into droplets. As an example, the atomizer can be attached to a part of the dispersion chamber to spray or inject the liquid mixture into the mist containing small droplets directly inside the dispersion chamber. Generally, a mist generator that produces a mist of droplets of a single size is desired. Alternatively, the mist can be generated outside the dispersion chamber and transported to the dispersion chamber.

[0124] The desired droplet size can be adjusted by adjusting the size of the liquid delivery / injection channel in the mist generator. Droplet sizes ranging from a few nanometers to hundreds of microns can be produced. The appropriate droplet size can be adjusted based on the choice of mist generator used, the liquid mixture composition, the temperature of the dispersion chamber, the flow rate of the first gas, and the residence time in the dispersion chamber. For example, a mist with droplet sizes between one tenth of a micron and one millimeter is produced in the dispersion chamber.

[0125] Without wishing to be bound by theory, in the method 800 of producing a particulate material, it is contemplated that two or more precursor compounds are prepared as a liquid mixture and then converted into droplets, each droplet having two or more precursors uniformly distributed together. The liquid mixture is then dehydrated by passing the droplets through a dispersion chamber, and a first gas stream is used to carry the mist within the dispersion chamber for a suitable residence time. It is also contemplated that the concentration of the precursor compounds in the liquid mixture and the droplet size of the mist of the liquid mixture can be adjusted to control the chemical composition, particle size, and particle size distribution of the final product particles of the battery material.

[0126] In one embodiment, one or more droplet streams are dispersed into a dispersion chamber at a first temperature and a desired first residence time to remove moisture therefrom. When the moisture in one or more droplet streams of a bulk compound is dispersed in a dispersion chamber filled with an airflow, a gas-liquid mixture consisting of a heated gas and liquid mixture is formed. Therefore, one embodiment of the present invention provides that the airflow flowing in the dispersion chamber is used as a gas source for forming a gas-liquid mixture in the dispersion chamber. In another embodiment, the gas flowing in the dispersion chamber is heated, and the thermal energy of the heated airflow is used as an energy source for drying reactions and other reactions in the dispersion chamber. The airflow can be heated to a temperature between 70°C and 600°C by an appropriate heating mechanism, such as an electric heater, a fuel combustion heater, etc.

[0127] In one configuration, the gas flow is preheated before flowing into the dispersion chamber. Optionally, one or more droplet streams can be dried by directly heating the dispersion chamber, such as heating the chamber body of the dispersion chamber. The advantages of using a heated gas are fast heat transfer, high temperature uniformity, and easy scale-up. The dispersion chamber can be any chamber, a furnace with a closed chamber body, such as a dome-shaped ceramic dispersion chamber, a quartz chamber, a tube chamber, etc. Optionally, the chamber body is made of an insulating material (such as ceramic, etc.) to prevent heat loss during the drying process.

[0128] The gas flow can be, for example, air, oxygen, carbon dioxide, nitrogen, hydrogen, an inert gas, a rare gas, and combinations thereof, etc. For example, heated air can be used as an inexpensive gas source and an energy source for drying the mist. The choice of the gas flow can be a gas that mixes well with the mist of the liquid mixture and dries the mist without reacting with the liquid mixture. In some cases, depending on the first temperature and the chemical composition of the liquid mixture, the chemicals in the droplets / mist may react with the gas flow and / or to a certain extent with each other during drying in the dispersion chamber. In addition, the residence time of the mist of the fully mixed liquid mixture compound in the dispersion chamber is adjustable, for example between one second and one hour, and can depend on the flow rate of the gas flow, and the length of the path through which the mist flows in the dispersion chamber.

[0129] Step 840 of method 800 includes treating one or more droplet streams in a reaction chamber of a treatment system. The reaction chamber can be a fluidized bed reactor, such as a circulating fluidized bed reactor, a bubbling fluidized bed reactor, an annular fluidized bed reactor, a flash fluidized bed reactor, and combinations thereof. Additionally, the reaction chamber can be any of a furnace reactor, such as a rotary furnace, a stirred furnace, a furnace with multiple temperature zones, and combinations thereof.

[0130] In one embodiment, one or more droplet streams are reacted into reaction products within a second residence time and reacted at a second temperature within the reaction chamber. The second residence time can be any residence time that allows the droplet stream to react completely, such as a residence time between one second and ten hours or longer. The reaction of the droplet stream within the reaction chamber may include any of oxidation, reduction, decomposition, combined reaction, phase inversion, recrystallization, single displacement reaction, double displacement reaction, combustion, isomerization, and combinations thereof. For example, the stream of droplets can be oxidized, such as oxidation of the liquid mixture compound to an oxide material.

[0131] In one embodiment, it is expected that the energy produced by the second gas flow that is heated to the reaction temperature and completes the reaction is reacted in the reaction chamber to obtain a kind of solid particles and obtain the crystal structure required for the final reaction product. The advantage of flowing air or heated gas is that heat transfer is faster, temperature distribution is uniform (especially in the high temperature range), and it is easy to expand the scale, etc. Exemplary second gas flow includes but is not limited to air, oxygen, carbon dioxide, oxidizing gas, nitrogen, inert gas, rare gas and combination thereof. In order to carry out oxidation reaction in the reaction chamber, oxidizing gas can be used as the second gas flow. In order to carry out reduction reaction in the reaction chamber, reducing gas can be used as the second gas flow.

[0132] In one embodiment, the reaction product (e.g., a gas-solid mixture of the oxidation reaction product mixed with a second gas and / or other gas phase byproducts or waste products, etc.) is discharged from the reaction chamber and cooled to obtain final solid particles of desired size, morphology and crystal structure, ready for further use in battery applications. For example, the reaction product can be slowly cooled to room temperature to avoid interfering with or disrupting the process of forming a stable energy state with uniform morphology and desired crystal structure.

[0133] Step 850 of method 800 includes closing one or more doors of the power nozzle module. Step 860 of method 800 includes moving one or more power injection modules in a second direction to be in a parking position. Optionally, step 810 of method 800 will be performed after step 860. Step 870 of method 800 includes moving one or more power injection modules in a third direction to position the one or more power injection modules in a maintenance position. Optionally, step 810 of method 800 will be performed after step 870.

[0134] Fig. 9 The steps of method 900 performed on a system having a power injection module are shown. Method 900 includes step 910, step 920, step 930 and step 940.

[0135] Step 910 of method 900 includes moving one or more powered jet modules in a first direction to be in a jetting position. Step 920 of method 900 includes moving one or more powered jet modules in a second direction to be in a parking position. Step 930 of method 900 includes moving one or more powered jet modules in a third direction to position the one or more powered jet modules in a maintenance position. Step 940 of method 900 includes cleaning one or more powered jet nozzles using one or more cleaning assemblies to remove unwanted deposits and contaminants. Optionally, steps 910, 920, or 930 may be performed after step 940 of method 900.

[0136] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope of the invention is determined by the appended claims.

Claims

1. A method for producing one or more particles of a metal-containing battery material for a battery cell using a liquid mixture, the method comprising: A processing system is provided, comprising a reaction chamber, a dispersion chamber having one or more openings, and one or more kinetic injection modules, wherein each kinetic injection module comprises: one or more doors; a power injector having an array of two or more nozzle holes on one side of the power injector, through each of the nozzle holes, the liquid mixture is injected into the dispersion chamber as one or more droplet streams, wherein the liquid mixture comprises a lithium-containing compound and one or more metal-containing compounds; moving the one or more power jet modules to a jetting position; opening the one or more doors on the one or more power jet modules; The one or more streams of droplets within the reaction chamber of the processing system are processed into one or more particles of the metal-containing battery material.

2. The method of claim 1 , further comprising closing the one or more doors of the power jet module.

3. The method of claim 1 , further comprising moving the one or more power jet modules to a parked position.

4. The method of claim 1 further comprising moving said one or more power jet modules to a maintenance position.

5. The method of claim 1, further comprising cleaning the one or more power ejectors using one or more cleaning assemblies to remove unwanted buildup of material and contaminants.

6. The method of claim 1, further comprising dispersing one or more uniform gas streams with the one or more droplet streams at a dispersion angle (α) between 0 degrees and 180 degrees in the dispersion chamber.

7. The method of claim 1, further comprising forming a gas-liquid mixture having the one or more uniform gas streams and the one or more droplet streams.

8. The method of claim 7, further comprising drying the gas-liquid mixture to obtain one or more particles of the metal-containing battery material.

9. The method of claim 1, further comprising annealing the one or more particles of the metal-containing battery material for a reaction time to form a final reaction product having a desired crystal structure.

10. The method according to claim 9, wherein the desired crystal structure of the final reaction product includes a structure consisting of a layered structure, a stratified structure, a spinel structure, and an olivine structure.

11. The method according to claim 1, characterized in that The dispersion chamber is placed vertically.

12. The method according to claim 1, characterized in that The dispersion chamber is placed horizontally.

13. The method according to claim 1, wherein the metal-containing battery material is selected from lithium nickel cobalt oxide (Li x Ni y Co z O2), nickel oxide lithium manganese oxide (Li x Ni y Mn z O2、Li x Ni y Mn z O4), nickel manganese cobalt oxide (Li in layered structure or layered structure) a Ni b Mn c Co d O e 、LiNi x Mn y Co z O2, where x+y+z=1, LiNi 0.33 Mn 0.33 Co 0.33 O2、LiNi 0.6 Mn 0.2 Co 0.2 O2,LiNi 0.5 Mn 0.3 Co 0.2 O2,LiNi 0.4 Mn 0.4 Co 0.2 O2,LiNi 0.7 Mn 0.15 Co 0.15 O2,LiNi 0.8 Mn 0.1 Co 0.1 O2), lithium cobalt aluminum oxide (Li x Co y Al z O n ), lithium nickel cobalt aluminum oxide (Li x Ni y Co z Al a O b) 、Sodium iron manganese oxide (Na x Fe y Mn z O2), mixed metal oxides with doped metals (Li a (Ni x Mn y Co z )MeO b (where Me = doping metal of Al, Mg, Fe, Ti, Cr, Zr or C), Li a (Ni x Mn y Co z )MeO b Fc (where Me = doping metal of Al, Mg, Fe, Ti, Cr, Zr or C)) and combinations thereof.

14. The method of claim 1, further comprising mating each of said motive jet modules with said each of said one or more openings on said dispersion chamber.

15. The method of claim 1, further comprising connecting said each door of said one or more motive jet modules to said each of said one or more openings of said dispersion chamber.

16. A method of producing one or more particles of a metal-containing battery material for a battery cell using a liquid mixture, the method comprising: A processing system is provided, comprising a reaction chamber, a dispersion chamber having one or more openings, and one or more kinetic injection modules, wherein each kinetic injection module comprises: one or more doors; a power injector having an array of two or more nozzle holes on one side of the power injector, through each of the nozzle holes, the liquid mixture is injected into the dispersion chamber as one or more droplet streams, wherein the liquid mixture comprises a lithium-containing compound and one or more metal-containing compounds; moving the one or more power jet modules to a jetting position; opening the one or more doors on the one or more power jet modules; Dispersing one or more uniform gas streams with the one or more droplet streams in the dispersion chamber at a dispersion angle (α) between 0 and 180 degrees; forming a gas-liquid mixture having the one or more uniform gas streams and the one or more liquid droplet streams; The gas-night mixture within the reaction chamber of the processing system is processed into one or more particles of the metal-containing battery material.

17. The method according to claim 16, characterized in that The dispersion chamber is placed vertically.

18. The method according to claim 16, characterized in that The dispersion chamber is placed horizontally.

19. A method of producing one or more particles of a metal-containing battery material for a battery cell using a liquid mixture, the method comprising: A processing system is provided, comprising a reaction chamber, a dispersion chamber having one or more openings, and one or more kinetic injection modules, wherein each kinetic injection module comprises: one or more doors; a power injector having an array of two or more nozzle holes on one side of the power injector, through each of the nozzle holes, the liquid mixture is injected into the dispersion chamber as one or more droplet streams, wherein the liquid mixture comprises a lithium-containing compound and one or more metal-containing compounds; moving the one or more power jet modules to a jetting position; opening the one or more doors on the one or more power jet modules; Dispersing one or more uniform gas streams with the one or more droplet streams in the dispersion chamber at a dispersion angle (α) between 0 and 180 degrees; forming a gas-liquid mixture having the one or more uniform gas streams and the one or more liquid droplet streams; drying the gas-liquid mixture to obtain one or more solid materials; The one or more solid materials are annealed for a reaction time to form one or more particles of a metal-containing battery material having a desired crystal structure.

20. The method according to claim 19, wherein the metal-containing battery material is selected from lithium nickel cobalt oxide (Li x Ni y Co z O2), nickel oxide lithium manganese oxide (Li x Ni y Mn z O2、Li x Ni y Mn z O4), nickel manganese cobalt oxide (Li in layered structure or layered structure) a Ni b Mn c Co d O e 、LiNi x Mn y Co z O2, where x+y+z=1, LiNi 0.33 Mn 0.33 Co 0.33 O2、LiNi 0.6 Mn 0.2 Co 0.2 O2,LiNi 0.5 Mn 0.3 Co 0.2 O2,LiNi 0.4 Mn 0.4 Co 0.2 O2,LiNi 0.7 Mn 0.15 Co 0.15 O2,LiNi 0.8 Mn 0.1 Co 0.1 O2), lithium cobalt aluminum oxide (Li x Co y Al z O n ), lithium nickel cobalt aluminum oxide (Li x Ni y Co z Al a O b ), sodium iron manganese oxide (Na x Fe y Mn z O2), mixed metal oxides with doped metals (Li a (Ni x Mn y Co z )MeO b (where Me = doping metal of Al, Mg, Fe, Ti, Cr, Zr or C), Li a (Ni x Mn y Co z )MeO b Fc (where Me = doping metal of Al, Mg, Fe, Ti, Cr, Zr or C)) and combinations thereof.

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