System with power jet module for preparing material for battery cell

Abstract

To provide a material for a battery cell that includes an active material produced in a processing system that produces a particulate material.SOLUTION: A material for a battery cell includes one or more particles of a metal oxide material obtained from a processing system including an array of power jet modules including one or more power jets adapted to eject a liquid mixture into one or more droplet streams and force the droplet streams into a processing system, each power jet having an array of nozzle orifices, each orifice adapted to eject the liquid mixture into a droplet stream, a dispersion chamber coupled to the power jet modules and adapted to receive the droplet streams, each power jet module adapted to be positioned at a first position connected to a corresponding opening in the chamber wall and at a second position remote from the opening, and a reaction chamber connected to the dispersion chamber and adapted to process the droplet streams into the metal oxide material.SELECTED DRAWING: Figure 1A

Description

[Technical Field]

[0001] The present invention relates generally to the preparation of materials for use in batteries. More specifically, the present invention relates to methods and systems for fabricating structured cathode or anode active materials for use in secondary batteries. [Background technology]

[0002] Much effort is being expended in developing advanced electrochemical battery cells to meet the growing demands in various consumer electronics, electric vehicles, and grid energy storage applications for high energy density, high power performance, large capacity, long cycle life, low cost, and high safety. In many cases, it is desirable to make batteries small, lightweight, and rechargeable (and thus reusable) to conserve space and material resources.

[0003] In electrochemically active battery cells, the cathode and anode are immersed in an electrolyte and electronically separated by a separator. The separator is typically made of a porous polymer membrane material, so that metal ions released from the electrodes into the electrolyte can diffuse through the separator's pores and migrate between the cathode and anode during battery charging and discharging. Battery cell types are typically named for the metal ions transported between their cathode and anode electrodes. Various rechargeable secondary batteries, such as nickel-cadmium batteries, nickel-metal hydride batteries, lead-acid batteries, lithium-ion batteries, and lithium-ion polymer batteries, have been developed for commercial use over the years. For commercial use, rechargeable secondary batteries are required to have high energy density, high power density, and be safe. However, a trade-off exists between energy density and power density.

[0004] Lithium-ion batteries are secondary batteries developed in the early 1990s. Compared to other secondary batteries, lithium-ion batteries offer high energy density, long cycle life, no memory effect, low self-discharge rate, and environmental benefits. Lithium-ion batteries have rapidly gained acceptance and have come to dominate the secondary battery sales market. However, the cost of producing various lithium battery materials for sale is significantly higher than other types of secondary batteries.

[0005] In lithium-ion batteries, the electrolyte primarily consists of a lithium salt (e.g., LiPF6, LiBF4, or LiClO4) in an organic solvent (e.g., ethylene carbonate, dimethyl carbonate, and diethyl carbonate) that allows lithium ions to move freely through the solvent. Typically, aluminum foil (e.g., 15–20 μm thick) and copper foil (e.g., 8–15 μm thick) are used as the current collectors for the cathode and anode electrodes, respectively. For the anode, micron-sized graphite (with a reversible capacity of approximately 330 mAh / g) is often used as the active material coated on the anode current collector. Graphite materials are often prepared from solid-state processes such as grinding and pyrolysis at extremely high temperatures (e.g., graphitization at approximately 3000 °C) without oxygen. Similar to active cathode materials, various solid-state materials with different crystal structures and capacities have been developed over the years. Examples of good cathode active materials include nanometer or micron sized lithium transition metal oxide materials and lithium ion phosphate.

[0006] The cathode active material is the most expensive component of a lithium-ion battery and determines, to a relatively large extent, the energy density, cycle life, manufacturing cost, and safety of a lithium battery cell. When lithium batteries were first commercialized, lithium cobalt oxide (LiCoO2) material was used as the cathode material, and it still holds a significant market share in the cathode active material market. However, cobalt is toxic and expensive. Other lithium transition metal oxide materials, such as layered LiMeO2 (where the metal Me = Ni, Mn, Co, etc.), have been used, such as LiNiO2, which has a reversible capacity of about 140-150 mAh / g / practical capacity. 0.33 Mn 0.33 Co 0.33 Recently, lithium metal phosphates (e.g., LiFePO4, approximately 140-150 mAh / g) have been developed as active cathode materials. When used as cathode materials, spinel-structured LiMnO4 materials exhibit poor battery cycle life, while olivine-structured LiFePO4 materials suffer from low energy density and poor low-temperature performance. While LiMeO2 materials have good electrochemical performance, previous LiMeO2 manufacturing processes can result in agglomerates, resulting in lower electrode densities compared to LiCoO2. In either case, previous processes for producing materials for use in batteries (especially cathode active materials) are costly due to the lengthy process times and significant energy consumption. Furthermore, previous material quality is inconsistent and manufacturing yields are poor.

[0007] Conventional material manufacturing processes, such as solid-state reactions (e.g., mixing solid precursors followed by calcination) and wet chemical processes (e.g., processing precursors in solution via coprecipitation, sol-gel, or hydrothermal reaction, followed by mixing and calcination), present significant challenges in creating nanostructured and microstructured materials. Consistently producing uniform solid materials (i.e., particles and powders) with desired particle size, morphology, crystal structure, particle shape, and even stoichiometry is difficult. Most conventional solid-state reactions require long calcination times (e.g., 4–20 hours) and additional annealing processes to ensure complete reaction, homogeneity, and grain growth. For example, spinel-structured LiMn2O4 and olivine-structured LiFePO4 materials produced by solid-state reactions require at least several hours of calcination in addition to a separate post-thermal annealing process (e.g., 24 hours), yet still exhibit poor quality consistency. One inherent problem associated with solid-state reactions is the thermal and chemical gradients (such as O2) inside the calciner, which limit the performance, consistency, and overall quality of the final product.

[0008] On the other hand, wet chemical processes, which are performed at low temperatures, typically involve fast chemical reactions but require a separate high-temperature firing process and even an additional annealing process at a later time. Furthermore, the chemical additives, gelling agents, and surfactants required in wet chemical processes add to the cost of material production (in purchasing additional chemicals and adjusting specific process sequences, ratios, pH, and temperatures) and can also affect the final composition of the resulting active material (thus often requiring additional steps to remove unwanted chemicals or filter the product). Furthermore, the primary particle size of the product powder produced by wet chemistry is very small and tends to aggregate into undesirably larger secondary particles, thereby affecting the energy packing density. Furthermore, the morphology of the resulting powder particles often exhibits undesirable amorphous aggregates, porous aggregates, wire-like shapes, rod-like shapes, flakes, etc. Uniform particle size and shape, which allows for high packing density, are desirable.

[0009] The synthesis of lithium cobalt oxide (LiCoO) materials is relatively simple and involves mixing a lithium salt (e.g., lithium hydroxide (LiOH) or lithium carbonate (LiCO)) with cobalt oxide (CoO) of the desired particle size, followed by furnace firing at very high temperatures for extended periods (e.g., 900°C for 20 hours) to ensure that the lithium metal diffuses into the cobalt oxide crystalline structure and forms the appropriate final product of LiCoO powder with a layered crystalline structure. This approach does not work for LiMeO because transition metals such as Ni, Mn, and Co do not diffuse well into each other and do not form a homogeneously mixed transition metal layer when their transition metal oxides or transition metal salts are directly mixed and reacted (solid-state firing). Therefore, conventional LiMeO2 manufacturing processes require purchasing or preparing transition metal hydroxide precursor compounds (e.g., Me(OH)2, Me=Ni, Mn, Co, etc.) from a wet chemical process of co-precipitation before making the final active cathode material (e.g., lithium NiMnCo transition metal oxide (LiMeO2)).

[0010] Because the water solubility of these Ni(OH)2, Co(OH)2, and Mn(OH)2 precursor compounds differs and they typically precipitate at different concentrations, the pH of the mixed solution of these precursor compounds must be adjusted, and ammonia (NH3) or other additives must be added slowly in small aliquots to ensure that nickel (Ni), manganese (Mn), and cobalt (Co) co-precipitate to form micron-sized nickel-manganese-cobalt hydroxide (NMC(OH)2) secondary particles. Such co-precipitated NMC(OH)2 secondary particles are often aggregates of nanometer-sized primary particles. Therefore, the final lithium NMC transition metal oxide (LiMeO2) made from the NMC(OH)2 precursor compound is also an aggregate. These aggregates tend to break up under high pressure during the electrode calendaring step and coating onto current collector foils. Therefore, when these lithium NMC transition metal oxide materials are used as cathode active materials, relatively low pressures must be used in the calendaring step, further limiting the electrode density of the resulting cathode.

[0011] In the conventional manufacturing process for LiMeO2 active cathode material, precursor compounds such as lithium hydroxide (LiOH) and transition metal hydroxide (Me(OH)2) are homogeneously mixed in solid form and stored in a thick Al2O3 crucible. The crucible is then placed in a furnace with a temperature ramp rate of 5–10 °C / min until the temperature reaches 900–950 °C and is fired for 10–20 hours. Because the precursor compounds are heated at high temperatures for long periods, adjacent particles sinter together, and a milling step is often required after firing. Therefore, particles of undesired sizes must be screened and removed after milling, further reducing the overall yield. High temperatures and long reaction times also result in the evaporation of lithium metal, typically requiring the addition of an additional amount of lithium precursor compound (e.g., 10%) during firing to ensure the final product has the correct lithium metal / transition metal ratio. Overall, such multi-step batch manufacturing processes are quite labor-intensive and energy-consuming, with process times of up to one week. Batch processes also increase the opportunity for impurities due to poor quality consistency in run-to-run control and low overall yields. Summary of the Invention [Problem to be solved by the invention]

[0012] Therefore, there is a need for improved processes and systems for producing high quality, structured active materials for battery cells.

[0013] The present invention relates generally to a system and method involving a power jet module coupled to a dispersion chamber for producing a product from a liquid mixture. More specifically, the present invention relates to a method and system for producing material particles (e.g., active electrode material, etc.) with desired crystal structure, crystal size, and crystal morphology. [Means for solving the problem]

[0014] In one embodiment, a processing system with a power jet module coupled to a dispersion chamber for producing a product from a liquid mixture is provided, the processing system including an array of one or more power jet modules adapted to eject the liquid mixture into one or more first droplet streams and force the one or more droplet streams into the processing system, each power jet module comprising a power jet. The processing system further includes a dispersion chamber coupled to the one or more power jet modules and adapted to receive the one or more droplet streams with one or more gas streams dispersing therein into a gas-liquid mixture. In one embodiment, the processing system further includes a reaction chamber connected to the dispersion chamber and adapted to process the gas-liquid mixture into a product.

[0015] In one embodiment, the dispersion chamber includes one or more apertures, and the power jets of each power jet module are adapted to be movably coupled to the apertures of the dispersion chamber, and the first actuator is controlled by the electronic control center and adapted to move the power jets to coincide with and connect to the apertures on the dispersion chamber.

[0016] In one embodiment, the first actuator is controlled by the electronic control center and adapted to move the power jet to coincide with and connect to the opening on the dispersion chamber. Further, the power jet of each power jet module is moved by the first actuator of the power jet module to a first position connected to the opening of the dispersion chamber. In one embodiment, each power jet module further includes a sealing element that seals each power jet module with the opening of the dispersion chamber in the first position, and a door adapted to allow the power jet to be positioned between a closed position and an open position by the second actuator. Further, the power jet of each power jet module is moved by the first actuator of the power jet module to a second position away from the opening of the dispersion chamber.

[0017] In one embodiment, the power jet of the processing system further includes an array of one or more nozzle orifices, each orifice adapted to eject the liquid mixture into one or more droplet streams. In one embodiment, the power jet module of the processing system further includes a cleaning assembly. The cleaning assembly of each power jet module further includes a movable cleaning blade element and a movable cleaning suction element. In one embodiment, the processing system further includes a buffer chamber having a gas distributor with one or more channels therein for forming one or more carrier gases into one or more gas streams. The processing system further includes an electronic control center.

[0018] In an alternative embodiment, the invention generally provides a processing system with power jet modules coupled to a dispersion chamber for producing a product from a liquid mixture, the processing system including: an array of one or more power jet modules adapted to eject the liquid mixture into one or more droplet streams, each power jet module comprising a power jet and a support frame for supporting movement of the power jet; and a dispersion chamber connected to the one or more power jet modules and adapted to receive the one or more droplet streams therein, the power jet of each power jet module adapted to be positioned at a first position connected to an opening of the dispersion chamber and at a second position remote from the opening of the dispersion chamber. In one embodiment, the processing system further includes a reaction chamber connected to the dispersion chamber and adapted to process the one or more droplet streams into the product.

[0019] In yet another embodiment, a method for producing a product from a liquid mixture using power jet modules coupled to a dispersion chamber is provided, comprising: moving each of one or more power jet modules in a first direction to a first position and connecting them to an opening in a dispersion chamber of a processing system; aligning each of the one or more power jet modules with a respective one or more openings on the dispersion chamber; and opening one or more doors of the one or more power jet modules. The method further comprises treating one or more droplet streams inside a reaction chamber of the processing system; closing the one or more doors of the power jet modules; and moving each of the one or more power jet modules in a second direction to a second position and away from the opening in the dispersion chamber.

[0020] So that the above-recited features of the invention can be understood in detail, a more particular description of the invention briefly summarized above can be made by reference to several embodiments, some of which are illustrated in the accompanying drawings. It should be noted, however, that the accompanying drawings illustrate only typical embodiments of the invention and are therefore not to be considered as limiting the scope of the invention, as other embodiments may be recognized that are equally effective for the invention. [Brief explanation of the drawings]

[0021] [Figure 1A] FIG. 1 is a perspective view of one embodiment of a system with a power jet module coupled to a dispersion chamber to produce a product from a liquid mixture. [Figure 1] FIG. 1 is a cross-sectional view of one embodiment of a system with a power jet module coupled to a dispersion chamber for producing a product from a liquid mixture. [Figure 2A] FIG. 1 is a cross-sectional view of an apparatus that can be used in a system with a power jet module coupled to a dispersion chamber to produce a product from a liquid mixture. [Figure 2B] 2B is a perspective view of the dispersion chamber of the apparatus of FIG. 2A that can be used in a system with a power jet module coupled to the dispersion chamber to produce a product from the liquid mixture. [Figure 2C] FIG. 1 is a cross-sectional view of a dispersion chamber of an apparatus that can be used in a system with a power jet module coupled to the dispersion chamber to produce a product from a liquid mixture. [Figure 2D] 10 illustrates the angle between the gas flow and the droplet flow inside the dispersion chamber according to one embodiment of the present invention. [Figure 2E] FIG. 1 is a perspective view of a power jet and an orifice thereon, according to one embodiment of the present invention. [Figure 3] 1 illustrates a perspective view of an exemplary power jet module configured in a dispersion chamber of a processing system in accordance with another embodiment of the present invention. [Figure 4] 1 illustrates a perspective view of an exemplary power jet module configured in a dispersion chamber of a processing system in accordance with another embodiment of the present invention. [Figure 5] 1 illustrates a perspective view of an exemplary power jet module configured in a dispersion chamber of a processing system in accordance with another embodiment of the present invention. [Figure 6] 1 illustrates a perspective view of an exemplary power jet module configured in a dispersion chamber of a processing system in accordance with another embodiment of the present invention. [Figure 7A] 1 is a cross-sectional view of an exemplary power jet module coupled to a dispersion chamber when the power jet module door is in the "open" position and a liquid mixture is being sprayed into the dispersion chamber. FIG. [Figure 7B] FIG. 1 is a cross-sectional view of an exemplary power jet module coupled to a dispersion chamber when the power jet module is in a "parked" position and the power jet module door is closed. [Figure 7C] FIG. 1 is a cross-sectional view of an exemplary power jet module coupled to a dispersion chamber when the power jet module is in an "on" position and the power jet module door is closed. [Figure 8] 10 illustrates method steps for functioning a system with a power jet module coupled to a dispersion chamber. [Figure 9]1 illustrates method steps for operating a system for producing particulate material from a liquid mixture, the system involving a power jet module coupled to a dispersion chamber. DETAILED DESCRIPTION OF THE INVENTION

[0022] The present invention generally provides a system and method involving a power jet module coupled to a dispersion chamber. The processing system includes an arrangement of one or more power jet modules, a system inlet, a reaction chamber, and a dispersion chamber. The processing system is useful for producing particulate materials and conducting a continuous process to save material production time and energy and solve problems such as high production costs, low yields, poor quality consistency, low electrode density, and low energy density encountered in conventional active material manufacturing processes.

[0023] In one aspect, a liquid mixture, which may be a liquid mixture metal, is rapidly ejected into a droplet stream by a power jet of a power jet module and then dispersed into a dispersion chamber. The droplet stream is continuously mixed with a gas to form a gas-liquid mixture and then delivered to a reaction chamber where it reacts. Alternatively, the droplet stream is delivered to a reaction chamber where it reacts.

[0024] In another aspect, the air or gas stream serves as a gas source for forming a gas-liquid mixture with the liquid mixture and as a carrier gas for delivering the gas-liquid mixture from the dispersion chamber to the reaction chamber. The gas may also serve as an energy source for the gas-liquid mixture to react in the reaction chamber if such gas is heated before entering the dispersion chamber.

[0025] The reaction products resulting from the reaction chamber are delivered out of the reaction chamber. The reaction products typically comprise solid material particles or fine powders of the oxide form of the liquid mixture composition (e.g., metal oxide materials, such as fine powders of mixed metal oxide materials) with a desired crystal structure, particle size, and morphology. Thus, high quality and uniform active particle materials can be obtained with significantly less time, labor, and monitoring than materials prepared from conventional manufacturing processes.

[0026] A system with a power jet module coupled to a dispersion chamber for producing a product from a liquid mixture. 1A is a perspective view of one embodiment of a processing system 100 for producing particulate material. This exemplary embodiment of the processing system 100 includes a system inlet 102 for delivering one or more gases through a gas line 106 and a system outlet 104 for delivering particulate material out of the processing system. The one or more gases may be selected from gas sources of air, oxygen, carbon dioxide, nitrogen gas, hydrogen gas, inert gases, noble gases, and combinations thereof, among others.

[0027] The processing system 100 includes a system inlet 102 for delivering one or more gases to 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 arrangement of one or more power jet modules 240A, 240B, 240C, 240D, etc. for ejecting 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 further includes a reaction chamber for processing the one or more droplet streams and one or more gases into a particulate material.

[0028] A liquid mixture is prepared from two or more precursor compounds and then converted into droplets, each droplet having two or more precursors uniformly distributed together. Water in the liquid mixture is then removed by passing the droplets through a dispersion chamber 220, and a gas flow is used to carry the vapor into the dispersion chamber for an appropriate residence time. It is further contemplated that the concentration of the precursor compounds in the liquid mixture and the droplet size of the vapor 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.

[0029] In another embodiment, as shown in FIG. 1A, the processing system 100 further includes at least one buffer chamber (e.g., 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 multiple uniform gas streams.

[0030] In a further embodiment, the processing system 100 also includes a dispersion chamber 220 and power jet modules 240A, 240B, and 240C for preparing the precursor liquid mixture to a desired diameter and delivering the desired precursor liquid mixture to the processing system. The power jet modules are attached to a portion of the dispersion chamber and can use air pressure to eject the liquid mixture and directly convert it into a vapor containing small droplets inside the dispersion chamber. Alternatively, the vapor can be generated outside the dispersion chamber and delivered to the dispersion chamber. Depending on the selection of the power jet module used, the liquid mixture compound, the dispersion chamber temperature, the gas flow rate, and the residence time inside the dispersion chamber, the appropriate droplet size can be adjusted. By way of example, vapor with liquid droplet sizes between 0.1 microns and 1 millimeter can be generated inside the dispersion chamber.

[0031] In one example, power jet module 240A is coupled to a portion of dispersion chamber 220 to generate a vapor of the liquid mixture (e.g., a large volume of small droplets) directly within the dispersion chamber. Generally, power jet module 240A is capable of generating a vapor of uniformly sized droplets. In one embodiment, dispersion chamber 220 is connected to one or more power jet modules 240A, 240B, and 240C, which receive a plurality of uniform gas streams from the buffer chamber and distribute the plurality of uniform gas streams, and one or more droplet streams are jetted from an arrangement of one or more power jet modules 240A, 240B, and 240C toward one another.

[0032] In another example, the dispersion chamber 220 is then connected to a reaction chamber 210 for processing one or more droplet streams and one or more gases into a particulate material, which in turn is connected to a system outlet 104 for delivering the particulate material out of the processing system.

[0033] 1B is a cross-sectional view of an exemplary processing system 100 that can be used to implement a fast, simple, continuous, and low-cost manufacturing process to produce particulate materials. In one embodiment, the processing system 100 further includes a gas distributor 232 attached to a chamber wall 238 of the buffer chamber 230, channels in the distributor 232 for delivering one or more gases F1 into multiple uniform gas flows F2 inside the processing system, a dispersion chamber 220, and one or more power jet modules 240A and 240B attached to a chamber wall 228 of the dispersion chamber 220.

[0034] In one embodiment, one or more gases F1 delivered to the buffer chamber 230 are pressurized downward and flow at a constant velocity through the channel 234 of the gas distributor 232, exiting the channel 234 into multiple uniform gas flows F2 and then flowing into the dispersion chamber 220. In one embodiment, the one or more gases F1 may be pumped through an air filter to remove any particles, droplets, or contaminants, and the flow rate of the gas may be adjusted by a valve or other means. In one embodiment, the flow rate of the multiple uniform gas flows F2 exiting the channel 234 is greater than the flow rate of the one or more gases F1. Furthermore, gases gather and converge in the direction of the multiple uniform gas flows F2.

[0035] In one embodiment, the power jet module 240A includes a power jet 242A for ejecting a liquid mixture supplied to the power jet module 240A into one or more droplet streams. The power jet module 240A further includes a support frame 244A for supporting the power jet module 240A, and one or more droplet streams F ejected from the power jet 242A mounted inside the support frame 244A. Aand pushing the liquid mixture supplied to the power jet module 240B into the dispersion chamber 220, and a connector 245A connecting the module actuator 246A and the power jet 242A. The power jet module 240B further includes a power jet 242B for ejecting the liquid mixture supplied to the power jet 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, and a connector 245A connecting the module actuator 246A and the power jet 242A to the dispersion chamber 220 ... power jet 242B for ejecting the liquid mixture supplied to the power jet module 240B into one or more droplet streams. The power jet module 240B further includes a B and a module actuator 246B mounted inside the support frame 244B for moving and pushing the module into the dispersion chamber 220, and a connector 245B connecting the module actuator 246B and the power jet 242B.

[0036] In one embodiment, the droplet stream F ejected into the dispersion chamber 220 A and multiple uniform gas flows F2 are spaced apart by a divergence angle α A The gas flow F2 and the droplet flow F are dispersed in a uniform manner. A Furthermore, the droplet flow F3 ejected into the dispersion chamber 220 is formed. B and multiple uniform gas flows F2 are spaced apart by a divergence angle α B The gas flow F2 and the droplet flow F are dispersed in a uniform manner. B In one embodiment, the dispersion chamber itself is maintained at a first temperature.

[0037] In another embodiment, one or more gases are heated to a drying temperature and mixed with the droplet stream to remove moisture from the droplet stream. This is designed to obtain spherical solid particles from a thoroughly mixed liquid mixture of two or more liquid mixtures after the liquid mixture vapor dries. In contrast, conventional solid production processes involve mixing or grinding a solid mixture of liquid mixture compounds, resulting in a heterogeneous mixture of the liquid mixture.

[0038] The one or more gases may be, for example, air, oxygen, carbon dioxide, nitrogen gas, hydrogen gas, an inert gas, a noble gas, or a combination thereof. For example, heated air can be used as an inexpensive gas and energy source for drying the droplet stream. The one or more gases selected may be gases that mix well with the precursor droplet stream and dry the vapor without reacting with the precursor. In some cases, the chemicals in the droplet stream may react with one or more gases and / or with each other to some extent during drying, depending on the drying temperature and chemical composition of the precursor. Furthermore, the residence time of the droplet stream of thoroughly mixed precursor compounds in the dispersion chamber can be adjusted and may range from, for example, 1 second to 1 hour, depending on the flow rate of the one or more gases and the path length the droplet stream must disperse and flow through the dispersion chamber.

[0039] In one embodiment, the processing system 100 further includes a reaction chamber 210 for receiving the gas-liquid mixture F3 and carrying out a desired reaction of the gas-liquid mixture F3 at a second temperature for a period of reaction time into a final reaction product F4. Finally, the final reaction product F4, which may be a product particle, can be delivered out of the system 100 through the system outlet 104 for further analysis of its properties (e.g., specific capacity, power performance, particulate charging cycle performance, etc.), particle size, morphology, crystal structure, etc., for use as a particulate material.

[0040] Optionally, 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 a gaseous stream of a preheated second gas to form a final reaction product F4 within the interior volume of the reaction chamber 210. The final reaction product F4 is heated by the thermal energy of the preheated second gas, and complete reaction is enhanced by continuously flowing the final reaction product F4 out of the reaction chamber 210 to a gas-solid separator coupled to the reaction chamber 210. The gas-solid separator is provided to remove by-products (and / or a portion of the reaction products) out of the system 100 via a separator outlet and recycle solid particles back to the reaction chamber 210 via the separator outlet. Product particles with a desired size, crystalline structure, and morphology are collected and delivered out of the gas-solid separator via the separator outlet.

[0041] Optionally, in another embodiment, the reaction chamber 210 is a bubbling-type fluidized-bed reactor. A gaseous stream of preheated second gas from a gas line is delivered to the reaction chamber 210, passes through a porous medium, and mixes with the gas-liquid mixture F3 delivered from the dispersion chamber 220 to generate a bubbling gaseous-solid mixture within the reaction chamber's internal volume. The thermal energy of the preheated second gas heats the bubbling gas-solid mixture, bubbling the gas-solid stream within the reaction chamber 210, thereby enhancing complete reaction. Once complete reaction has occurred, gaseous byproducts are removed from the reaction chamber 210 via the reactor outlet. The final reaction product F4 with the desired crystal structure, morphology, and size is collected and delivered from the reaction chamber 210 via the system outlet 104.

[0042] Optionally, in another embodiment, reaction chamber 210 is an annular fluidized bed reactor. A gaseous stream of preheated second gas from a gas line is delivered to reaction chamber 210 and redirected toward an additional gas stream (e.g., gas stream) to promote thorough mixing of the heated gas with the gas-liquid mixture F3 delivered from dispersion chamber 220, producing a homogeneously mixed gas-solid mixture within the reactor's reaction chamber interior volume. Once complete reaction has occurred, gas by-products are removed from reaction chamber 210 via the reactor outlet. Product particles with the desired crystal structure, morphology, and size are collected and delivered from reaction chamber 210 via system outlet 104.

[0043] Optionally, in another embodiment, the reaction chamber 210 is a flash-type fluidized-bed reactor. The reaction chamber 210 receives the gas-liquid mixture F3 from the dispersion chamber 220 and mixes it with a preheated gas flow from a gas line to form a gas-solid mixture. The gas-solid mixture passes through the body of a tubular reactor connected to the reaction chamber 210. The gas-solid mixture must pass through a long internal path, which uses the thermal energy of the heated gas to promote complete reaction. Gas by-products are then removed from the reaction chamber 210 via the reactor outlet, and product particles with the desired crystal structure, morphology, and size are collected and delivered out of the reaction chamber 210 via the system outlet 104. Note that an additional gas line inlet can be used to deliver heated or cooled air or cooled or heated gas to the reaction chamber 210.

[0044] In one embodiment, the final reaction product F4 includes, among others, metal oxide materials, doped metal oxide materials, inorganic metal salts. Examples of metal oxide materials include, but are not limited to, titanium oxide (Ti x O y , e.g., Ti2O5, etc.), chromium oxide (Cr x O y , e.g., Cr2O7, etc.), tin oxide (Sn x O y , e.g., S n O2, SnO, SnSiO3, etc.), copper oxide (Cu x O y , for example, CuO, CuO, etc.), aluminum oxide (Alx O y , for example, Al2O3, etc.), manganese oxide (Mn x O y ), iron oxide (Fe x O y For mixed metal oxide materials, it may be desirable to adjust the composition of the final reaction product material by the ratio of the liquid mixture compounds added to the liquid mixture added to the processing system 100. In one embodiment, two or more metals (Me x Me' y O z ) to obtain metal oxides with the following properties. Examples include lithium transition metal oxides (LiMeO2), lithium titanium oxides (e.g., Li4Ti5O 12 ), lithium cobalt oxide (e.g., LiCoO), lithium manganese oxide (e.g., LiMnO), lithium nickel oxide (e.g., LiNiO), lithium iron phosphate (e.g., LiFePO), lithium cobalt phosphate (e.g., LiCoPO), lithium manganese phosphate (e.g., LiMnPO), lithium nickel phosphate (e.g., LiNiPO), sodium iron oxide (e.g., NaFeO), sodium iron phosphate (e.g., NaFePO).

[0045] In another embodiment, the final reaction product F4 comprises a metal oxide with three or four interlayer metals. Examples of 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., layered or multilayered Li a Ni b Mn c Co d O e and / or LiNi x Mny Co z NMC oxide materials such as O2, where x+y+z=1, e.g., 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, etc.), and / or mixed metal oxides with doping metals. Other examples include lithium cobalt aluminum oxide (e.g., Li x Co y Al z O n ), lithium nickel cobalt aluminum oxide (e.g., Li x Ni y Co z Al a O b ), sodium iron manganese oxide (e.g., Na x Fe y Mn z O2). In another example, mixed metal oxides are obtained with doping metals, for example. In particular, Li a (Ni x Mn y Co z )MeO b (where Me = Al, Mg, Fe, Ti, Cr, Zr, or C doping metal), Li a (Ni x Mn y Co z )MeO b F c (where Me = Al, Mg, Fe, Ti, Cr, Zr, or C doped metal) is obtained.

[0046] Other metal oxide materials can also be obtained, including, among others, one or more of lithium (Li), nickel (Ni), manganese (Mn), cobalt (Co), aluminum (Al), titanium (Ti), sodium (Na), potassium (K), rubidium (Rb), vanadium (V), cesium (Cs), copper (Cu), magnesium (Mg), and iron (Fe). Furthermore, the metal oxide materials can exhibit metallic crystalline structures in the form of layered spinel, layered olivine, and the like. Furthermore, the morphology of the final reaction product F4 is present as a desired solid powder. The particle size of the solid powder ranges from 10 nm to 100 μm.

[0047] In one embodiment, the processing system 100 is connected to an electronic control unit 300, which includes a CPU 340, for automated control of the processing system 100. The electronic control unit 300 adjusts various processing parameters (e.g., flow rate, mixture ratio, temperature, residence time, etc.) within the processing system 100. For example, the flow rate of the liquid mixture into the system 100 can be adjusted. As another example, the droplet size and yield of one or more droplet streams generated by the power jet module can be adjusted. Additionally, the flow rates and temperatures of the various gases flowing within the gas line 102 can be controlled by the electronic control unit 300. Furthermore, the electronic control unit 300 is adapted to control the temperature and residence time of the various gas-liquid mixtures and solid particles at desired levels at various locations.

[0048] Optionally, in one embodiment, the processing system 100 further includes a first separator, the first separator connected to the dispersion chamber 230 and adapted to collect the gas-liquid mixture F3 from the dispersion chamber and separate it into a first type of solid particles and waste. Optionally, the first separator is connected to a drying chamber, the drying chamber connected to the dispersion chamber 230 and adapted to collect the gas-liquid mixture F3 from the dispersion chamber, dry the gas-liquid mixture F3 into gas-solid particles, deliver the gas-solid particles to the first separator, and separate it into the first type of solid particles and waste within the first separator. In one embodiment, the first separator further includes a first separator outlet connected to the reaction chamber 210 and adapted to deliver the first type of solid particles to the reaction chamber 210, and a second separator outlet adapted to deliver the waste out of the first separator.

[0049] In one embodiment, one or more separators, coolant lines, and / or heat exchangers collect and cool the final reaction product F4, and once cooled, it exits the system 100. The final reaction product F4 may include an oxidized liquid mixture (such as an oxide material) suitable for packing into a battery cell. Additional pumps may also be installed to achieve the desired pressure gradient.

[0050] 2A is a cross-sectional view of a buffer chamber 230 for performing a process for preparing a particulate material according to one embodiment of the present invention. Referring also to FIG. 1, the buffer chamber 230 in FIG. 2A is a cross-section taken along dashed line BB'. In one embodiment, the buffer chamber 230 includes a cylinder gas distributor 232 for delivering one or more gases from a system inlet to a plurality of integrated gases, the cylinder gas distributor 232 being enclosed within an inner chamber wall 238 of the buffer chamber 230 and positioned at the bottom of the buffer chamber 230, and channels 234 of the gas distributor 232 for delivering one or more gases in a uniform direction and at a constant flow rate.

[0051] 2B is a perspective view of the buffer chamber 230. The buffer chamber 230 includes a cylinder gas distributor 232 enclosed within a chamber wall 238 of the buffer chamber 230, and a channel 234 of the gas distributor 232.

[0052] 2C is a cross-sectional view of a dispersion chamber 220 configured in the processing system 100 according to one embodiment of the present invention. Referring also to FIG. 1, the cross-section of the buffer chamber 220 in FIG. 3A is taken along dashed line AA'. The dispersion chamber 220 is surrounded by a chamber wall 228.

[0053] In one embodiment, an array of one or more power jet modules (respectively, power jet module 240A, power jet module 240B, power jet module 240C, and power jet module 240D) are positioned in one or more openings 222A, 222B, 222C, and 222D in chamber wall 228 of dispersion chamber 220. In one embodiment, power jet modules 240A-240D can be attached to chamber wall 228 of dispersion chamber 220 in one arrangement shown in FIG. 3A. In that arrangement, each of the four power jets can be configured on chamber wall 228 adjacent to and evenly spaced from one another on the same horizontal line of chamber wall 228.

[0054] In one embodiment, the power jet module 240A includes a power jet 242A for ejecting a liquid mixture supplied to the power jet module 240A into one or more droplet streams. The power jet module 240A further includes a support frame 244A for supporting the power jet module 240A, and one or more droplet streams F ejected from the power jet 242A mounted inside the support frame 244A. Aand into dispersion chamber 220, and a connector 245A connecting module actuator 246A and power jet 242A. Similarly, power jet module 240B includes power jet 242B, support frame 244B, module actuator 246B, and connector 245B. Similarly, power jet module 240C includes power jet 242C, support frame 244C, module actuator 246C, and connector 245C. Also, power jet module 240D includes power jet 242D, support frame 244D, module actuator 246D, and connector 245D.

[0055] In one embodiment, the power jets 242A-242D are positioned near the top of a vertically positioned dispersion chamber 220 (e.g., a dome-shaped dispersion chamber, etc.), and F A ~F D The droplet stream is injected into the dispersion chamber 220 and passes vertically downward through the dispersion chamber. Alternatively, the power jets 242A-242D can be positioned near the bottom of a vertically positioned dispersion chamber 220, injecting the droplet stream upward into the dispersion chamber (as shown in FIG. 3B), allowing for a longer residence time of the liquid flow occurring within the dispersion chamber. In another embodiment, when the dispersion chamber 220 (e.g., a tubular dispersion chamber, etc.) is positioned horizontally and the power jets 242A-242D are positioned near one end of the dispersion chamber 220, the vapor flow delivered from one end of the dispersion chamber 220 through the other end can pass through a path within the dispersion chamber 220 for the length of its residence time.

[0056] In addition to the liquid mixture flow, the dispersion chamber 220 is also filled with a gas flow. A gas distributor 232 is coupled to the end of the buffer chamber and adapted to flow a plurality of integrated gases F2 into the dispersion chamber 220. Simultaneously with the formation of the droplet flow inside the dispersion chamber 220 as the droplet flow is transported through the dispersion chamber 220, the gas flow of the plurality of integrated gases F2 can be delivered to the dispersion chamber 220, which may or may not remove moisture from the vapor, forming a gas-liquid mixture in the direction of F3 containing the liquid mixture. The gas flow of the plurality of integrated gases F2 can also be delivered to the dispersion chamber 220 before the vapor is formed, filling the interior volume of the dispersion chamber 220 and preheating it to a first temperature before the droplet flow is generated inside the dispersion chamber 220.

[0057] In one example, the gas distributor 232 is connected to an end of the buffer chamber 230, which is connected to the top of the dispersion chamber 310, and the gas distributor 232 delivers a plurality of combined gases F2 to the dispersion chamber 220, where the gas F2 mixes with the droplet stream generated by a power jet module attached to the chamber wall 228 of the dispersion chamber 220. In one embodiment, the combined gases F2 are preheated to a temperature of 70°C to 600°C and mixed with the droplet stream to remove moisture from the droplet stream. In another embodiment, the combined gases F2 are used without preheating to ensure that the gas-liquid mixture formed inside the dispersion chamber 220 is uniformly mixed with the gas.

[0058] FIG. 2D illustrates the dispersion angles of multiple combined gas F2 and droplet streams FA inside the dispersion chamber 220 configured in the processing system 100 of FIG. 1, according to one embodiment of the present invention.

[0059] In FIG. 2D, inside dispersion chamber 220, droplet stream F A is the dispersion angle α A It is shown that the gas F2 is dispersed into multiple integrated gases F2 at a dispersion angle α A is the droplet flow F relative to the vertical axis Z A The angle between the direction of the gas F2 and the multiple integrated gases F2 is measured and further shown in a three-dimensional perspective view of the XYZ axis setting.

[0060] In one embodiment, the liquid mixture (e.g., droplet stream F A The liquid flow of the droplet stream F) and the gas flow (e.g., the multiple integrated gases F2) may collide with each other inside the dispersion chamber at an angle of 0 to 180 degrees. A and the air flow of gas flow F2 may flow in a straight line, a spiral, a tangled manner, and / or in other ways.

[0061] In one embodiment, the droplet stream F A and the plurality of integrated gases F2 are arranged at an angle α A (0≦α A ≦180°), and the droplets can merge and mix inside the dispersion chamber (for example, become parallel flows). A The combined gases F2 may flow at various angles toward each other and / or toward the periphery of the chamber body, facilitating the formation of spiral, intertwining, and / or other air flows inside the dispersion chamber 220. In one embodiment, the droplet stream and gas stream may be configured at an angle α less than 90 degrees and may meet and mix inside the dispersion chamber. In another embodiment, the droplet stream and gas stream F A The gas flow F2 is configured at an angle α of 90 degrees and can merge and mix inside the dispersion chamber. A and gas flow F2 may flow at various angles toward each other and / or toward the outer periphery of the chamber body, promoting the formation of spiral, intertwining, and / or other air flows inside the dispersion chamber 220.

[0062] For example, as shown in the example of Figure 3B, the gas flow and the liquid flow of the droplet stream flowing inside the dispersion chamber can be configured to flow in a co-current manner. The advantages of co-current flow include, among other things, a shorter residence time, a lower particle drying temperature, and a higher particle separation efficiency. In another embodiment, also shown in the example of Figure 3B, the gas flow and the liquid flow of the droplet stream of the integrated gas stream flowing inside the dispersion chamber can be configured to flow in a convection manner. The advantages of convection include, among other things, a longer residence time and a higher particle drying temperature.

[0063] In another embodiment, the droplet stream F A and gas flow F2 is configured at an angle α of 180 degrees and flows convectively. In an alternative embodiment, the dispersion chamber 220 can be positioned horizontally. Similarly, the droplet flow F A 1, once the droplet stream of the liquid mixture is formed into a gas-liquid mixture with the gas, the gas-liquid mixture is delivered to the reaction chamber 210 through the dispersion chamber 220.

[0064] 2F is a perspective view of a power jet 242A, according to one embodiment of the present invention. The power jet 242A is connected to a liquid source 720 that stores a desired amount of liquid mixing compound, and to an electronic control unit 300 for directing and controlling the delivery of the liquid mixing compound from the liquid source 720 to the power jet 242A.

[0065] In another configuration, the liquid mixture within the liquid source 720 can be pumped from the liquid source 720 to the power jet 242A. The pumping of the liquid mixture can be configured, for example, to continuously deliver a desired amount (e.g., regulated by a throttle valve or other means) to achieve good process throughput of the processing system 100. In another configuration, the power jet 242A is positioned outside the dispersion chamber 220, and the liquid flow generated by the power jet 242A is delivered to the dispersion chamber 220 via a chamber inlet.

[0066] In one embodiment, the power jet 242A is a rectangular parallelepiped structure having six rectangular faces at right angles to each other. Additionally, the power jet 242A has a nozzle array 480A on one side of the power jet 242A. In one embodiment, the nozzle array 480A is on a side of the power jet 242A whose base width is shorter than its side length and is comprised of 3 x 10 evenly spaced orifices 402A, forming a rectangular shape. In another embodiment, the nozzle array 480A is comprised of another pattern of orifices.

[0067] In other embodiments, the power jet has a different shape and configuration, such as a cylindrical configuration with horizontal parallel faces and a circular or elliptical cross section. Additionally, the power jet has an array of nozzles on one horizontal parallel face of the power jet. In one embodiment, the nozzle array consists of a single orifice.

[0068] 3 illustrates a perspective view of an example of a power jet module configured in a dispersion chamber of a processing system. In one embodiment, a power jet module 240A for ejecting a liquid mixture into one or more droplet streams and forcing the one or more droplet streams into a processing system includes a power jet 242A for ejecting a liquid mixture supplied to the power jet module 240A into one or more droplet streams. The power jet module 240A further includes a support frame 244A for supporting movement of the power jet 242A, a first module actuator 246A for moving the connected power jet to align with an opening on the dispersion chamber, and a connector 245A connecting the first module actuator 246A and the power jet 242A. The power jet module further includes a sealing element 249A, a door 247A, a second module actuator 248A, and a third module actuator 250A.

[0069] 3, dispersion chamber 220 includes one or more openings 222A, 222B, 222C, 222D, 222E, and 222F, which are positioned in a chamber wall of dispersion chamber 220 and adapted to connect to and mate with the power jets of the power jet module on one side of the power jets with the nozzle arrays. In one embodiment, the shape of the one or more openings and the arrangement of the one or more openings are shown in FIG. 3, and the one or more openings are rectangular with a base width shorter than the side lengths, and are positioned adjacent to each other at equal distances on the same horizontal line of the chamber wall.

[0070] 3, the dispersion chamber 220 is filled with a plurality of integrated gases F2 delivered from the buffer chamber of the processing chamber. In one embodiment, to transport the droplet stream through the dispersion chamber 220, the plurality of integrated gases F2 may or may not remove moisture from the vapor simultaneously with the formation of the droplet stream ejected from the power jet of the power jet module inside the dispersion chamber 220, forming a gas-liquid mixture including the liquid mixture and the plurality of integrated gases in the direction of F3. Also, the gas flow of the plurality of integrated gases F2 may be delivered to the dispersion chamber 220 before the droplet stream is formed, and may fill the internal volume of the dispersion chamber 220 and optionally be preheated to a first temperature before the droplet stream is generated inside the dispersion chamber 220.

[0071] In one embodiment, one or more openings 222A-222F are positioned near the top of a vertically positioned dispersion chamber 220 (e.g., a dome-shaped dispersion chamber, etc.) and are connected to and adapted to a power jet module for injecting a droplet stream into the dispersion chamber 220 and passing vertically downward through the dispersion chamber. Alternatively, one or more openings 222A-222F can be positioned near the bottom of a vertically positioned dispersion chamber 220, allowing them to be connected to and adapted to a power jet module for injecting the droplet stream upward into the dispersion chamber by increasing the residence time of the liquid flow generated within the dispersion chamber. In another embodiment, when the dispersion chamber 220 (e.g., a tubular dispersion chamber, etc.) is positioned horizontally and one or more openings 222A-222F are positioned near one end of the dispersion chamber 220, these openings are adapted to and connected to a power jet module for injecting a droplet stream delivered from one end of the dispersion chamber 220 through the other end, allowing the droplet stream to pass through a path within the dispersion chamber 220 for the length of its residence time.

[0072] Furthermore, in one embodiment, the droplet streams ejected into the dispersion chamber 220 are dispersed together with the plurality of uniform gas streams F2 to form a gas-liquid mixture F3 comprising the plurality of uniform gas streams F2 and the droplet streams. In one embodiment, the dispersion chamber itself is maintained at a first temperature.

[0073] In one embodiment of the present invention, the direction of the multiple uniform gas flows F2 delivered to the dispersion chamber 220 is parallel to the chamber wall of the dispersion chamber 220. And, the direction of the gas-liquid mixture F3 delivered 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 direction of the multiple uniform gas flows F2 delivered to the dispersion chamber 220 and the direction of the gas-liquid mixture F3 delivered through the dispersion chamber 220 are different.

[0074] 4 illustrates, in a perspective view, an example of one or more power jet modules configured in a dispersion chamber of a processing system. In one embodiment, a power jet module 440A for ejecting a liquid mixture into one or more droplet streams and forcing the one or more droplet streams into a processing system includes a power jet 442A for ejecting a liquid mixture supplied to the power jet module 440A into one or more droplet streams. The power jet module 440A further includes a support frame 444A for supporting movement of the power jet 442A, a first module actuator 446A for moving the connected power jet to align with an opening on the dispersion chamber, and a connector 445A connecting the first module actuator 446A and the power jet 442A. The power jet module further includes a sealing element 449A, a door 447A, a second module actuator 448A, and a third module actuator 450A. In the same embodiment, a power jet module 440G for ejecting a liquid mixture into one or more droplet streams and forcing the one or more droplet streams into a processing system includes a power jet 442G for ejecting a liquid mixture supplied to the power jet module 440G into one or more droplet streams. The power jet module 440G further includes a support frame 444G for supporting movement of the power jet 442G, a first module actuator 446G for moving the connected power jet to align with an opening on the dispersion chamber, and a connector 445G connecting the first module actuator 446G and the power jet 442G. The power jet module further includes a sealing element 449G, a door 447G, a second module actuator 448G, and a third module actuator 450G.

[0075] 4, the dispersion chamber 420 includes one or more openings 422A, 422B, 422C, 422D, 422E, 422F, 422G, 422H, 422I, 422J, 422K, and 422L, which are positioned in a chamber wall of the dispersion chamber 420 and adapted to connect to and mate with the power jets of the power jet module on one side of the power jets associated with the nozzle array. In one embodiment, the shape of the one or more openings is shown in FIG. 4, where the one or more openings are rectangular with a base width shorter than the side lengths. In one embodiment, the arrangement of the one or more openings is further shown in FIG. 4, where the openings 422A-422F are positioned adjacent to each other and equidistant from each other on the same horizontal line of the chamber wall in a first row, and the openings 422G-422L are positioned adjacent to each other and equidistant from each other on the same horizontal line of the chamber wall in a second row different from the first row. Furthermore, the openings 422A to 422L are not positioned on the same vertical line of the chamber wall so as not to overlap one another.

[0076] 4, the dispersion chamber 420 is filled with a plurality of integrated gases F2 delivered from the buffer chamber of the processing chamber. In one embodiment, to transport the droplet stream through the dispersion chamber 420, the plurality of integrated gases F2 may or may not remove moisture from the vapor simultaneously with the formation of the droplet stream ejected from the power jet of the power jet module inside the dispersion chamber 420, forming a gas-liquid mixture including the liquid mixture and the plurality of integrated gases in the direction of F3. Also, the gas flow of the plurality of integrated gases F2 may be delivered to the dispersion chamber 420 before the droplet stream is formed, and may fill the internal volume of the dispersion chamber 420 and optionally preheat it to a first temperature before the droplet stream is generated inside the dispersion chamber 420.

[0077] In one embodiment, one or more openings 422A-422F are positioned near the top of a vertically positioned dispersion chamber 420 (e.g., a dome-shaped dispersion chamber, etc.) and are connected to and adapted to a power jet module for injecting a droplet stream into the dispersion chamber 420 and passing vertically downward through the dispersion chamber. Additionally, in the same embodiment, one or more openings 422G-422L are positioned near the bottom of the dispersion chamber 420. In another embodiment, when the dispersion chamber 420 (e.g., a tubular dispersion chamber, etc.) is positioned horizontally and one or more openings 422A-422F are positioned near one end of the dispersion chamber 420, these openings are adapted to and connected to a power jet module for injecting a droplet stream that is delivered from one end of the dispersion chamber 420 through the other end, allowing the droplet stream to pass through a path inside the dispersion chamber 420 for the length of its residence time. Additionally, in the same embodiment, one or more openings 422G-422L are positioned near the other end of the dispersion chamber 420.

[0078] Furthermore, in one embodiment, the droplet streams ejected into the dispersion chamber 420 are dispersed together with the plurality of uniform gas streams F2 to form a gas-liquid mixture F3 comprising the plurality of uniform gas streams F2 and the droplet streams. In one embodiment, the dispersion chamber itself is maintained at a first temperature.

[0079] In one embodiment of the present invention, the direction of the multiple uniform gas flows F2 delivered to the dispersion chamber 420 is 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 direction of the multiple uniform gas flows F2 delivered to the dispersion chamber 420 and the direction of the gas-liquid mixture F3 delivered through the dispersion chamber 420 are different.

[0080] 5 illustrates a perspective view of an example of a power jet module configured in a dispersion chamber of a processing system. In one embodiment, a power jet module 540A for ejecting a liquid mixture into one or more droplet streams and forcing the one or more droplet streams into a processing system includes a power jet 542A for ejecting a liquid mixture supplied to the power jet module 540A into one or more droplet streams. The power jet module 540A further includes a support frame 544A for supporting movement of the power jet 542A, a first module actuator 546A for moving the connected power jet to align with 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 further includes a sealing element, a door, a second module actuator, and a third module actuator.

[0081] 5, dispersion chamber 520 includes one or more openings 522A, 522B, 522C, 522D, 522E, and 522F positioned in a chamber wall of dispersion chamber 520, adapted to connect to and mate with the power jets of the power jet module on one side of the power jets, with nozzle rows, and having a base width greater than its side lengths. In one embodiment, the shape of the one or more openings and the arrangement of the one or more openings are shown in FIG. 5, where the one or more openings are rectangular with a base width greater than its side lengths, and positioned adjacent to each other at equal distances on the same vertical line of the chamber wall.

[0082] In one embodiment, the power jets 522A-522F are positioned near the left end of the horizontally positioned dispersion chamber 520 (e.g., a tubular dispersion chamber, etc.) and are connected to and adapted to a power jet module for injecting a droplet stream into the dispersion chamber 520 and passing it from one end of the dispersion chamber to the other. Alternatively, the power jets 522A-522F can be positioned near the right end of the horizontally positioned dispersion chamber 520, allowing them to be connected to and adapted to a power jet module for injecting a droplet stream upward into the dispersion chamber over the length of the residence time of the liquid flow generated within the dispersion chamber. In one embodiment, the dispersion chamber itself is maintained at a first temperature.

[0083] In one embodiment of the present invention, the direction of the multiple uniform gas flows F2 delivered to the dispersion chamber 520 is 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 direction of the multiple uniform gas flows F2 delivered to the dispersion chamber 520 and the direction of the gas-liquid mixture F3 delivered through the dispersion chamber 520 are different.

[0084] In one embodiment of the present invention, the direction of the multiple uniform gas streams F2 delivered to the dispersion chamber is parallel to the chamber wall of the dispersion chamber 520. And, the direction of the gas-liquid mixture F3 formed by dispersing the multiple uniform gas streams F2 into droplet streams from the power jet delivered through the dispersion chamber 520 is also parallel to the chamber wall of the dispersion chamber 520.

[0085] 6 illustrates a perspective view of an example of a power jet module configured in a dispersion chamber of a processing system. In one embodiment, a power jet module 640A for ejecting a liquid mixture into one or more droplet streams and forcing the one or more droplet streams into a processing system includes a power jet 642A for ejecting a liquid mixture supplied to the power jet module 640A into one or more droplet streams. The power jet module 640A further includes a support frame 644A for supporting movement of the power jet 642A, a first module actuator 646A for moving the connected power jet to align with an opening on the dispersion chamber, and a connector connecting the first module actuator 646A and the power jet 642A. The power jet module further includes a sealing element, a door, a second module actuator, and a third module actuator.

[0086] 6, dispersion chamber 620 includes one or more openings 622A, 622B, 622C positioned in a chamber wall of dispersion chamber 620 and adapted to connect to and mate with the power jets of the power jet module on one side of the power jets with the nozzle array. In one embodiment, the shape of the one or more openings and the arrangement of the one or more openings are shown in FIG. 6, where the one or more openings are rectangular with a base width greater than the side lengths, and are positioned adjacent to and equidistant from each other on the same horizontal line of the chamber wall.

[0087] 6, the dispersion chamber 620 is filled with a plurality of integrated gases F2 delivered from the buffer chamber of the processing chamber. In one embodiment, to transport the droplet stream through the dispersion chamber 620, the plurality of integrated gases F2 may or may not remove moisture from the vapor simultaneously with the formation of the droplet stream ejected from the power jet of the power jet module inside the dispersion chamber 620, forming a gas-liquid mixture including the liquid mixture and the plurality of integrated gases in the direction of F3. Also, the gas flow of the plurality of integrated gases F2 may be delivered to the dispersion chamber 620 before the droplet stream is formed, and may fill the internal volume of the dispersion chamber 620 and optionally preheat it to a first temperature before the droplet stream is generated inside the dispersion chamber 620.

[0088] In one embodiment, one or more openings 622A-622C are positioned near the top of a vertically positioned dispersion chamber 620 (e.g., a dome-shaped dispersion chamber, etc.) and are adapted to connect to and adapt to a power jet module for injecting a droplet stream into the dispersion chamber 620 and passing vertically downward through the dispersion chamber. Alternatively, one or more openings 622A-622C can be positioned near the bottom of a vertically positioned dispersion chamber 620, allowing them to connect to and adapt to a power jet module for injecting the droplet stream upward into the dispersion chamber by increasing the residence time of the liquid flow generated within the dispersion chamber. In another embodiment, when the dispersion chamber 620 (e.g., a tubular dispersion chamber, etc.) is positioned horizontally and one or more openings 622A-622C are positioned near one end of the dispersion chamber 620, these openings are adapted to connect to and adapt to a power jet module for injecting a droplet stream delivered from one end of the dispersion chamber 620 through the other end, allowing the droplet stream to 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.

[0089] In one embodiment of the present invention, the direction of the multiple uniform gas streams F2 delivered to the dispersion chamber is parallel to the chamber wall of the dispersion chamber 620. And, the direction of the gas-liquid mixture F3 formed by dispersing the multiple uniform gas streams F2 into droplet streams from the power jet delivered through the dispersion chamber 620 is also parallel to the chamber wall of the dispersion chamber 620.

[0090] 7A is a front view of an exemplary power jet module adapted to be coupled to a dispersion chamber. The power jet module is sealed at an opening in the chamber wall 228 of the dispersion chamber by a sealing element 249A of the power jet module 240A, and the power jet of the power jet module is positioned in a first position such that the power jet 242A is positioned to connect to the opening of the dispersion chamber. In one embodiment, the power jet 242A is configured to generate one or more droplet streams F at the first position under the control of an electronic control center. A can be sprayed into the dispersion chamber.

[0091] 3, the power jet module further includes a support frame 244A for supporting movement of the power jet 242A, a first module actuator 246A, 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 element 252A and a movable suction element 254A moved by the third module actuator 250A.

[0092] In one embodiment, the first module actuator 246A is controlled by an electronic control center and is adapted to move the power jet by moving a connector 245A connecting the first module actuator 246A and the power jet 242A along the direction of "H" perpendicular to the wall of the dispersion chamber. When moved by the first module actuator 246A along the direction of "H" toward the opening on the dispersion chamber, the connector 245A simultaneously moves the power jet 242A along the direction of "H" toward the opening on the dispersion chamber. When moved by the first module actuator 246A along the direction of "H" away from the opening on the dispersion chamber, the connector 245A simultaneously moves the power jet 242A along the direction of "H" away from the opening on the dispersion chamber. When the power jet 242A moves to coincide with and connect with the opening on the dispersion chamber, the first position of the power jet 242A is reached.

[0093] In one embodiment, the second module actuator 248A is adapted to move the door 247A along a direction V1 parallel to a chamber wall of the dispersion chamber, and the first position of the power jet 242A is reached when the door 247A moves to an open position where the power jet 242A passes through the door 247A and connects to an opening on the dispersion chamber.

[0094] 7B is a front view of an exemplary power jet module adapted to be coupled to a dispersion chamber. The power jet module is sealed at an opening in the chamber wall 228 of the dispersion chamber by a sealing element 249A of the power jet module 240A, and the power jets of the power jet module are positioned at a second position where the power jets 242A of the power jet module 240A are positioned away from the opening of the dispersion chamber. In one embodiment, the power jets 242A are configured to generate one or more droplet streams F at the second position under the control of an electronic control center. A Do not spray into the dispersion chamber.

[0095] 3 , the power jet module further includes a support frame 244A for supporting movement of the power jet 242A, a first module actuator 246A, 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, which includes a movable cleaning blade element 252A and a movable suction element 254A moved by the third module actuator 250A. In one embodiment, the electronic control center includes a connecting wire 310 connected to and controlling the movement of the second module actuator 248A along the “V1” direction, a connecting wire 320 connected to and controlling the movement of the third module actuator 250A along the “V2” direction, a connecting wire 330 connected to and controlling the movement of the first module actuator 248A along the “H” direction, and a CPU 340.

[0096] 7A, in one embodiment, the first module actuator 246A is controlled by an electronic control center and adapted to move the power jet 242A by moving the connector 245A connecting the first module actuator 246A and the power jet 242A along the direction of "H" perpendicular to the chamber wall of the dispersion chamber. When the power jet 242A moves away from the opening on the dispersion chamber, the second position of the power jet 242A is reached.

[0097] 7A, in one embodiment, the second module actuator 248A is adapted to move the door 247A along a direction "V1" parallel to the chamber wall of the dispersion chamber. The second position of the power jet 242A is reached when the door 247A moves to a closed position that blocks the power jet 242A from passing through the door 247A.

[0098] 7C is a front view of an exemplary power jet module adapted to be coupled to a dispersion chamber. The power jet module is sealed at an opening in the chamber wall 228 of the dispersion chamber by a sealing element 249A of the power jet module 240A and includes a cleaning assembly of the power jet module 240A for cleaning the power jet of the power jet module. As shown in FIG. 7C, the power jet module 240A further includes a cleaning assembly including a movable cleaning blade element 252A and a movable suction element 254A that are moved by a third module actuator 250A along the "V2" direction.

[0099] In one embodiment, the third module actuator 250A is adapted to move the cleaning blade element 252A along a direction V2 parallel to a surface with the array of one or more nozzle orifices of the power jet 242A to clean the surface with the cleaning blade element 252A, where the power jet 252A is in a second position where the power jet 252A is positioned away from the opening on the chamber wall of the dispersion chamber and the cleaning blade element 252A is attached to the surface with the array of one or more nozzle orifices. In one embodiment, referring also to FIG. 7B , the power jet 242A moves to the second position and the door 247A moves to the closed position.

[0100] Method of operating a system involving a power jet module coupled to a dispersion chamber to produce a product from a liquid mixture - Patent Application 20070122997 8 shows steps of a method 800 for operating a system involving a power jet module coupled to a dispersion chamber. Method 800 includes steps 810, 820, 830, 840, 850, 860, and 870.

[0101] Step 810 of method 800 includes moving one or more power jet modules in a first direction to an ejection position. Step 820 of method 800 includes opening one or more doors of the one or more power jet modules. Step 830 of method 800 includes ejecting the liquid mixture into one or more droplet streams with one or more power jets of the one or more power jet modules.

[0102] In one embodiment, two or more precursors are used to form a liquid mixture. Generally, liquid precursor compounds can be directly prepared to form a liquid mixture at a desired concentration. Solid precursor compounds can be dissolved or dispersed in a suitable solvent (e.g., water, alcohol, isopropanol, or any other organic or inorganic solvent, and combinations thereof) to form an aqueous solution, slurry, gel, aerosol, or any other suitable liquid mixture. For example, a desired molar ratio of two or more solid precursors can be prepared to form a liquid mixture by, for example, measuring appropriate amounts of two or more solid precursors into a container with an appropriate amount of solvent. Depending on the solubility of the precursors in the solvent, pH, temperature, and mechanical agitation and mixing can be adjusted to obtain a liquid mixture and sufficiently dissolve and / or evenly distribute the precursor compounds.

[0103] In one example, two or more metal-containing precursors are mixed into a liquid mixture to obtain a final reaction product of a mixed metal oxide material. Examples of 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( Nickel hydroxide (Mn(OH)), manganese formate (Mn(CHO)), manganese chloride (MnCl), nickel sulfate (NiSO), nickel nitrate (Ni(NO), nickel carbonate (NiCO), nickel acetate (Ni(CHCOO)), nickel hydroxide (Ni(OH)), nickel formate (Ni(CHO)), nickel chloride (NiCl), aluminum (Al)-containing compounds, titanium (Ti)-containing compounds, sodium (Na)-containing compounds, potassium (K)-containing compounds, rubidium (Rb)-containing compounds, vanadium (V)-containing compounds, cesium (Cs)-containing compounds, chromium (Cr)-containing compounds, copper (Cu)-containing compounds, magnesium (Mg)-containing compounds, iron (Fe)-containing compounds, and combinations thereof.

[0104] Without wishing to be bound by theory, it is contemplated that to prepare an oxide material containing two or more different metals, two or more metal-containing precursor compounds may be used as the source of each metal element, and all of the required metal elements may first be mixed into a liquid mixture (e.g., a solution, a slurry, or a gel mixture) so that the two or more different metals can be uniformly mixed in the desired ratio. For example, one or more metal salts with high water solubility may be used to prepare the aqueous solution, slurry, or gel liquid mixture. For example, metal nitrates, metal sulfates, metal chlorides, metal acetates, and metal formates may be used. Organic solvents (e.g., alcohol, isopropanol, etc.) may be used to dissolve or disperse metal-containing precursors with low water solubility. In some cases, the pH value of the liquid mixture may be adjusted to increase the solubility of one or more precursor compounds. Optionally, chemical additives, gelling agents, and surfactants (e.g., ammonia, EDTA, etc.) may be added to the liquid mixture to facilitate dissolving or dispersing the precursor compounds in the selected solvent.

[0105] In one embodiment, the power jet module is selected from the group of nozzles, sprayers, atomizers, or any other vapor generators. The power jet module uses air pressure to eject the liquid mixture, converting it into droplets. As an example, an atomizer can be attached to a portion of the dispersion chamber and spray or inject the liquid mixture, directly converting the liquid mixture into a vapor containing small droplets inside the dispersion chamber. Generally, a vapor generator that produces a vapor of uniform droplet size is desirable. Alternatively, the vapor can be generated outside the dispersion chamber and delivered to the dispersion chamber.

[0106] The desired droplet diameter of the droplet stream can be adjusted by adjusting the size of the liquid delivery / injection channel in the vapor generator. Droplet diameters ranging from a few nanometers to hundreds of micrometers can be generated. Depending on the selection of the vapor generator used, the liquid mixture compound, the temperature of the dispersion chamber, the flow rate of the first gas, and the residence time inside the dispersion chamber, the appropriate droplet diameter can be adjusted. As an example, vapor with liquid droplet diameters of 0.1 microns to 1 millimeter can be generated inside the dispersion chamber.

[0107] Without wishing to be bound by theory, in method 800 for producing a particle material, two or more precursor compounds are prepared into a liquid mixture and then converted into droplets, each droplet having two or more precursors uniformly distributed together. Water in the liquid mixture is then removed by passing the droplets through a dispersion chamber, and a gas flow of a first gas is used to transport vapor into the dispersion chamber for a suitable residence time. It is further contemplated that the concentration of the precursor compounds in the liquid mixture and the droplet size of the vapor 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.

[0108] In one embodiment, one or more droplet streams are dispersed in a dispersion chamber at a first temperature for a desired first residence time to remove moisture. When the dispersion of moisture from one or more droplet streams of precursor compound occurs in a dispersion chamber filled with a gas flow, a gas-liquid mixture is formed, consisting of a heated first gas and a liquid mixture. Thus, in one embodiment of the present invention, the gas flowing in the dispersion chamber is used as a gas source to form the 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 gas flow serves as an energy source for carrying out drying reactions and other reactions inside the dispersion chamber. The gas stream can be heated to a temperature between 70°C and 600°C by passing it through a suitable heating mechanism, such as an electric heater or a fuel-fired heater.

[0109] In one configuration, the gas stream is preheated before flowing into the dispersion chamber. Optionally, drying one or more droplet streams can be performed by directly heating the dispersion chamber (e.g., by heating the chamber body of the dispersion chamber). The advantages of using heated gas include, among others, fast heat transfer, high temperature uniformity, and easy performance enhancement. The dispersion chamber can be any chamber, such as a dome-shaped ceramic dispersion chamber, a quartz chamber, a tubular chamber, or a furnace with an enclosed chamber body. Optionally, the chamber body is made of a thermal insulating material (e.g., ceramic) to prevent heat loss during drying.

[0110] The gas stream can be, for example, air, oxygen, carbon dioxide, nitrogen gas, hydrogen gas, inert gas, noble gas, or a combination thereof. For example, heated air can be used as an inexpensive gas and energy source for drying the vapor. The selected gas stream can be a gas that mixes sufficiently with the vapor of the gas-liquid mixture and dries the vapor without reacting with the liquid mixture. In some cases, the chemicals of the droplets / vapor can react with the gas stream and / or with each other to some extent during drying in the dispersion chamber, depending on the first temperature and the chemical composition of the liquid mixture. Furthermore, the residence time of the vapor of the thoroughly mixed liquid mixture compound in the dispersion chamber can be adjusted and can be, for example, from 1 second to 1 hour, depending on the flow rate of the gas stream and the path length the vapor must flow through the dispersion chamber.

[0111] Step 840 of method 800 includes treating one or more droplet streams inside a reaction chamber of a processing 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. Furthermore, the reaction chamber can be any furnace-type reactor, such as a rotary furnace, a stirred furnace, a multi-temperature zone furnace, and combinations thereof.

[0112] In one embodiment, the one or more droplet streams react to form reaction products inside the reaction chamber at a second temperature for a second residence time. The second residence time can be any residence time required to effect complete reaction of the droplet streams, such as from 1 second to 10 hours, or longer than 10 hours. The reaction of the droplet streams in the reaction chamber can include any of oxidation, reduction, decomposition, combination reaction, phase transformation, recrystallization, simple replacement reaction, double replacement reaction, combustion, isomerization, and combinations thereof. For example, the droplet streams can be oxidized, e.g., by oxidizing a liquid mixture compound to an oxide material.

[0113] In one embodiment, energy from a second gas stream heated to a reaction temperature is used to obtain certain types of solid particles from the reaction of the droplet stream in the reaction chamber to sufficiently complete the reaction and obtain the desired crystalline structure of the final reaction product. The advantages of flowing preheated air or gas include, among other things, fast heat transfer, uniform temperature distribution (especially in high-temperature zones), and easy performance enhancement. Exemplary second gas streams include, but are not limited to, air, oxygen, carbon dioxide, oxidizing gas, nitrogen gas, inert gas, noble gas, and combinations thereof. For oxidation reactions inside the reaction chamber, an oxidizing gas can be used as the second gas stream. For reduction reactions inside the reaction chamber, a reducing gas can be used as the second gas stream.

[0114] In one embodiment, the reaction product (e.g., a gas-solid mixture of the oxidation reaction product mixed with the second gas and / or other gas-phase by-products, or waste products, etc.) is delivered outside the reaction chamber and cooled to obtain final solid particles of the desired size, morphology, and crystalline structure, ready for further use in a battery. For example, the reaction product may be cooled slowly to room temperature to avoid interrupting or failing the process of forming its stable energy state with a uniform morphology and desired crystalline structure.

[0115] Step 850 of method 800 includes closing one or more doors of a power jet module. Step 860 of method 800 includes moving one or more power jet modules in a second direction to a parked position. Optionally, step 860 is followed by step 810 of method 800. Step 870 of method 800 includes moving one or more power jet modules in a third direction to position the one or more power jet modules in an operational position. Optionally, step 870 is followed by step 810 of method 800.

[0116] 9 shows steps of a method 900 for functioning a system with a power jet module. The method 900 includes steps 910, 920, 930, and 940.

[0117] Step 910 of method 900 includes moving one or more power jet modules in a first direction to a jetting position. Step 920 of method 900 includes moving one or more power jet modules in a second direction to a parked position. Step 930 of method 900 includes moving one or more power jet modules in a third direction to position the one or more power jet modules in an active position. Step 940 of method 900 includes cleaning one or more power jets using one or more cleaning assemblies to remove accumulated unwanted material and contaminants. Optionally, any of steps 910, 920, or 930 can be performed after step 940 of method 900.

[0118] 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, which scope is determined by the claims that follow.

Claims

1. A material for a battery cell, comprising: comprising one or more non-agglomerated particles of a non-composite metal oxide material consisting of lithium nickel cobalt oxide, lithium nickel manganese oxide, lithium cobalt aluminum oxide, lithium nickel cobalt aluminum oxide, sodium iron manganese oxide, mixed metal oxides with doped metals, or combinations thereof, having a size of 10 nm to 100 μm and exhibiting a crystalline structure in the form of a layered structure; the one or more particles of metal oxide material are obtained from a processing system using a liquid mixture comprising a lithium-containing compound and one or more metal-containing compounds; The processing system includes: an array of one or more power jet modules including one or more power jets adapted to eject the liquid mixture into one or more droplet streams and force the one or more droplet streams into the processing system, each power jet module comprising a power jet, each power jet having an array of one or more nozzle orifices, each orifice adapted to eject the liquid mixture into one or more droplet streams; a dispersion chamber coupled to the one or more power jet modules and adapted to receive the one or more droplet streams with one or more gas streams dispersing therein, the dispersion chamber including a chamber wall having one or more openings, each power jet module adapted to be positioned at a first position connected to a corresponding opening in the chamber wall and a second position spaced apart from the opening; a reaction chamber connected to the dispersion chamber and adapted to process the one or more droplet streams into the metal oxide material.

2. 10. The material of claim 1, wherein the power jet of each power jet module is adapted to be movably coupled to a corresponding opening in the chamber wall of the dispersion chamber.

3. The material of claim 2 , wherein each power jet module further comprises a support frame and a first actuator for supporting movement of the power jet.

4. 4. The material of claim 3, wherein the first actuator is controlled by an electronic control center and adapted to move the power jet to mate with an opening on the dispersion chamber.

5. 4. The material of claim 3, wherein the power jet of each power jet module is moved by the first actuator of the power jet module to a first position connected to the opening of the dispersion chamber.

6. 4. The material of claim 3, wherein each power jet module further comprises a sealing element that seals each power jet module at the opening of the dispersion chamber in the first position.

7. 4. The material of claim 3, wherein the power jet of each power jet module is moved by the first actuator of the power jet module to a second position away from the opening of the dispersion chamber.

8. 7. The material of claim 6, wherein the power jet of each power jet module further comprises a door, the power jet adapted to be positioned in a closed position and an open position by a second actuator.

9. The material of claim 1 , wherein each power jet module further comprises a cleaning assembly.

10. The material of claim 9 , wherein the cleaning assembly of each power jet module further comprises a movable cleaning blade element.

11. The material of claim 9 , wherein the cleaning assembly of each power jet module further comprises a movable suction element.

12. 10. The material of claim 1, further comprising a buffer chamber having a gas distributor with one or more channels therein for forming one or more carrier gases into one or more gas streams.

13. The material of claim 1 , wherein the processing system further comprises an electronic control center.

14. A material for a battery cell, comprising: comprising one or more non-agglomerated particles of a non-composite metal oxide material consisting of lithium nickel cobalt oxide, lithium nickel manganese oxide, lithium cobalt aluminum oxide, lithium nickel cobalt aluminum oxide, sodium iron manganese oxide, mixed metal oxides with doped metals, or combinations thereof, having a size of 10 nm to 100 μm and exhibiting a crystalline structure in the form of a layered structure; the one or more particles of metal oxide material are obtained from a processing system using a liquid mixture comprising a lithium-containing compound and one or more metal-containing compounds; The processing system includes: an array of one or more power jet modules adapted to eject the liquid mixture into one or more droplet streams, each power jet module comprising a power jet and a support frame for supporting movement of the power jet; a dispersion chamber connected to the one or more power jet modules and adapted to receive the one or more droplet streams therein, the power jet of each power jet module being adapted to be positioned at a first location connected to an opening of the dispersion chamber and at a second location remote from the opening of the dispersion chamber; a reaction chamber connected to the dispersion chamber and adapted to process the one or more droplet streams into the metal oxide material.

15. 15. The material of claim 14, wherein each power jet module further comprises a sealing element that secures each power jet module in the opening of the dispersion chamber in the first position.

16. 15. The material of claim 14, wherein the power jet comprises an array of one or more nozzle orifices, each orifice adapted to eject the liquid mixture into one or more droplet streams.

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