System and method with a power jet module

Abstract

To provide a method for manufacturing an active material for a battery cell structured with a high quality.SOLUTION: A processing system and a method for generating a particle material are provided. The processing system comprises: one or more power jet modules 240A to C each ejecting a liquid mixture to make a droplet flow in general, and adopted so as to eject it to a processing system 100; a dispersion chamber 220; and a reaction chamber 210 adopted to process the droplet flow to make a product material. The method includes: moving each of the one or more power jet modules in a first direction and connecting it to an opening of the dispersion chamber; matching each of the one or more power jet modules to each opening; opening the one or more doors of the power jet module; processing the droplet flow in an inner side of the reaction chamber; closing the one or more doors of the power jet module; and moving each of the one or more power jet modules in the second direction to separate it from the opening.SELECTED DRAWING: Figure 1A

Description

Technical Field

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

Background Art

[0002] In order to meet the growing demand in the use of various household appliances, electric vehicles, and grid energy storage with respect to high energy density, high power performance, large capacity, long cycle life, low cost, and high safety, much effort has been spent on the development of advanced electrochemical battery cells. In many cases, it is desirable to miniaturize, lightweight, and rechargeable (and thus reusable) the battery to save space and material resources.

[0003] In an electrochemically active battery cell, the cathode and anode are immersed in an electrolyte solution and electronically separated by a separator. The separator is generally made of a porous polymer membrane material. As a result, metal ions released from the electrodes into the electrolyte solution diffuse through the pores of the separator and can move between the cathode and anode during charging and discharging of the battery. The type of battery cell is usually named after the metal ions carried between its 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 use in commercial applications, rechargeable secondary batteries are required to have high energy density, high power density, and be safe. However, there is a trade-off between energy density and power density.

[0004] Lithium-ion batteries are secondary batteries developed in the early 1990s. Compared with other secondary batteries, lithium-ion batteries bring advantages such as high energy density, long cycle life, elimination of memory effect, low self-discharge rate, and environmental friendliness. Lithium-ion batteries have been rapidly accepted and come to occupy the majority of the secondary battery sales market. However, the cost of manufacturing various lithium battery materials for commercial use is considerably higher than that of other types of secondary batteries.

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

[0006] The cathode active material is the most expensive component of a lithium-ion battery, and to a relatively large extent, the energy density, cycle life, manufacturing cost, and safety of a lithium battery cell are confirmed. When lithium batteries were first commercialized, lithium cobalt oxide (LiCoO2) materials were used as cathode materials, 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., for example, LiNi 0.33 Mn 0.33 Co 0.33 O2) with a reversible capacity / practical capacity of about 140 - 150 mAh / g, spinel-structured LiMn2O4 (reversible capacity / practical capacity of about 110 - 120 mAh / g), and olivine-type lithium metal phosphates (e.g., LiFePO4 with a reversible capacity / practical capacity of about 140 - 150 mAh / g) have recently been developed as active cathode materials. When used as cathode materials, spinel-structured LiMn2O4 materials show insufficient battery cycle life, and olivine-type LiFePO4 materials have problems of low energy density and insufficient low-temperature performance. Regarding LiMeO2 materials, although their electrochemical performance is good, the previous manufacturing process of LiMeO2 may obtain mostly aggregates, and as a result, the electrode density of most LiMeO2 materials is lower compared to LiCoO2. In any case, previous processes for manufacturing materials (especially cathode active materials) for use in batteries are mostly time-consuming and consume a significant amount of energy, resulting in high costs. Moreover, previous material quality has no consistency and the manufacturing yield is poor.

[0007] Conventional material manufacturing processes such as solid-state reactions (e.g., mixing of solid precursors followed by firing) and wet chemical processes (e.g., treating precursors in solution by coprecipitation, sol-gel, or hydrothermal reaction, etc., followed by mixing and firing) have significant challenges when making nanostructured and micron-structured materials. It is difficult to produce uniform solid materials (i.e., particles and powders) with the desired particle size, morphology, crystal structure, particle shape, and furthermore, the desired stoichiometry without variation. Most conventional solid-state reactions require long firing times (e.g., 4 - 20 hours) and additional annealing processes to achieve complete reaction, homogeneity, and grain growth. For example, spinel-type structured LiMn₂O₄ and olivine-type LiFePO₄ materials produced by solid-state reactions require at least several hours of firing in addition to another post-thermal annealing process (e.g., 24 hours), and still show insufficient quality consistency. One of the fundamental problems associated with solid-state reactions is that the temperature gradient and chemical gradient (such as O₂, etc.) inside the firing furnace limit the performance, quality consistency, and overall quality of the final product.

[0008] On the other hand, wet chemical processes carried out at low temperatures usually involve fast chemical reactions, but another high-temperature firing process and further additional annealing processes are required later. Furthermore, the chemical additives, gelling agents, and surfactants required in wet chemical processes are added to the material manufacturing cost (when purchasing additional chemicals and when adjusting specific process sequences, ratios, pH, and temperature), and can similarly affect the final composition of the active materials produced (therefore, often additional steps to remove unnecessary chemicals or filter the products are required). Additionally, the primary particle size of the product powders produced by wet chemistry is very small and tends to aggregate into undesirably large secondary particles, which affects the energy integration density. Also, the morphology of the similarly produced powder particles often shows undesired amorphous aggregates, porous aggregates, wire-like, rod-like, flake-like, etc. A uniform particle size and shape that enable high integration density are desirable.

[0009] The synthesis of lithium cobalt oxide (LiCoO2) materials is relatively simple and involves mixing a lithium salt (e.g., lithium hydroxide (LiOH) or lithium carbonate (Li2CO3)) with cobalt oxide (Co3O4) of a desired particle size, and then firing in a heating furnace at an ultra-high temperature for a long time (e.g., 20 hours at 900°C), ensuring that lithium metal diffuses into the crystal structure of cobalt oxide to form an appropriate final product of LiCoO2 powder with a layered crystal structure. This approach is not effective for LiMeO2. The reason is that transition metals such as Ni, Mn, and Co do not diffuse sufficiently into each other, and when their transition metal oxides or transition metal salts are directly mixed and reacted (solid-phase firing), a uniformly mixed transition metal layer is not formed. Therefore, in the conventional manufacturing process of LiMeO2, before making the final active cathode material (e.g., lithium NiMnCo transition metal oxide (LiMeO2)), it is required to purchase a transition metal hydroxide precursor compound (e.g., Me(OH)2, Me = Ni, Mn, Co, etc.) or prepare the transition metal hydroxide precursor compound from a co-precipitation wet chemical process.

[0010] The water solubilities of these precursor compounds of Ni(OH)2, Co(OH)2, and Mn(OH)2 are different, and since they usually precipitate at different concentrations, it is necessary to adjust the pH of the mixed solution of these precursor compounds, and it is necessary to slowly add ammonia (NH3) or other additives in small aliquots, by which nickel (Ni), manganese (Mn), and cobalt (Co) co-precipitate together to ensure that micron-sized secondary particles of nickel-manganese-cobalt hydroxide (NMC(OH)2) can be formed. Such secondary particles of co-precipitated NMC(OH)2 are often aggregates of primary particles with nanometer diameters. Therefore, the final lithium NMC transition metal oxide (LiMeO2) made from the precursor compounds of NMC(OH)2 is also an aggregate. These aggregates tend to break under high pressure during the electrode calendaring step and during coating onto the current collector foil. Therefore, when these lithium NMC transition metal oxide materials are used as the cathode active material, it is necessary to use a relatively low pressure in the calendaring step, further limiting the electrode density of the manufactured cathode.

[0011] In the conventional manufacturing process of the active cathode material of LiMeO2, precursor compounds such as lithium hydroxide (LiOH) and transition metal hydroxide (Me(OH)2) are uniformly mixed while in solid state and stored in a thick Al2O3 crucible. Next, the crucible is placed in a heating furnace with a temperature rising rate set at 5 - 10 °C / min until it reaches 900° - 950 °C, and is fired for 10 - 20 hours. Since the precursor compounds are heated at high temperature for a long time, adjacent particles are sintered together, and thus, in many cases, a fine pulverization step is required after firing. Therefore, particles of unwanted size need to be sorted and removed after pulverization, and furthermore, the overall yield decreases. High temperature and long reaction time also cause the vaporization of lithium metal, and generally, it is required to add an additional amount of lithium precursor compound equivalent to 10% during firing to ensure that the final product has an appropriate ratio of lithium metal / transition metal. Overall, the process time required for such a multi-step batch manufacturing process takes up to one week at the longest, so it is quite labor-intensive and consumes a significant amount of energy. Also, the batch process increases the chance of impurities due to insufficient quality consistency of Run-to-Run control and low overall yield.

Summary of the Invention

Problems to be Solved by the Invention

[0012] Therefore, there is a need to improve the process and system for manufacturing active materials for high-quality and structured battery cells.

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

Means for Solving the Problems

[0014] In one embodiment, a processing system is provided that includes a power jet module coupled to a dispersion chamber for generating a product from a liquid mixture, the power jet module adapted to eject a liquid mixture into one or more first droplet streams and to impel 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, the dispersion chamber being coupled to the one or more power jet modules and adapted to receive the one or more droplet streams in a state where one or more gas streams are dispersed therein such that a gas-liquid mixture is formed. In one embodiment, the processing system further includes a reaction chamber, the reaction chamber being 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 openings. And the power jet of each power jet module is adapted to be movably coupled to the opening of the dispersion chamber, and a first actuator is controlled by an electronic control center to move the power jet and connect it so as to coincide with the opening on the dispersion chamber.

[0016] In one embodiment, a first actuator is controlled by an electronic control center to move the power jet and connect it so as to coincide with the opening on the dispersion chamber. Further, the power jet of each power jet module is moved by a first actuator of the power jet module and positioned at 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 at the opening of the dispersion chamber at the first position, and a door adapted such that the power jet is positioned at a closed position and an open position by a second actuator. Further, the power jet of each power jet module is moved by a first actuator of the power jet module and positioned at 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 being adapted to eject a liquid mixture into one or more streams of droplets. 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 formed therein for shaping 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 present invention generally provides a processing system with a power jet module coupled to a dispersion chamber for generating a product from a liquid mixture, the array of one or more power jet modules adapted to eject a liquid mixture into one or more streams of droplets, each power jet module comprising a power jet and a support frame for supporting movement of the power jet, the array of one or more power jet modules, and a dispersion chamber connected to the one or more power jet modules and adapted to receive the one or more streams of droplets therein, the power jet of each power jet module being positioned at a first position connected to an opening of the dispersion chamber and adapted to be positioned at a second position remote from the opening of the dispersion chamber. In certain embodiments, the processing system further includes a reaction chamber connected to the dispersion chamber and adapted to process the one or more streams of droplets into a product.

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

[0020] To enable a more detailed understanding of the features enumerated above of the present invention, a more specific description of the present invention, briefly summarized above, may be made by reference to a plurality of embodiments, some of which are illustrated in the accompanying drawings. However, it should be noted that the accompanying drawings show only typical embodiments of the present invention and are therefore not considered to limit the scope of the present invention, and other embodiments equally effective for the present invention may be recognized.

Brief Description of the Drawings

[0021]

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[0022] The present invention generally provides a system with a power jet module coupled to a dispersion chamber and a method thereof. The processing system includes an array of one or more power jet modules, a system inlet, a reaction chamber, and a dispersion chamber. The processing system is useful for performing a continuous process to produce particulate material, save material production time and energy, and solve problems of high production cost, low yield, insufficient quality consistency, low electrode density, and low energy density as seen in conventional active material production processes.

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

[0024] In another aspect, an air stream or a 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. Also, the gas can serve as an energy source for the gas-liquid mixture reacting in the reaction chamber if such gas is heated before entering the dispersion chamber.

[0025] The reaction product resulting from the reaction chamber is delivered out of the reaction chamber. The reaction product typically includes solid material particles or fine powders of an oxidized 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 particulate material 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 generating a product from a liquid mixture FIG. 1A is a perspective view of one embodiment of a processing system 100 for generating particulate material. This exemplary embodiment of processing system 100 includes a system inlet 102 for delivering one or more gases through gas line 106 and a system outlet 104 for delivering particulate material out of the processing system. The one or more gases can be selected, in particular, from gas sources of air, oxygen, carbon dioxide, nitrogen gas, hydrogen gas, inert gas, noble gas, and combinations thereof.

[0027] Processing system 100 includes a system inlet 102 for delivering one or more gases to the processing system, a buffer chamber 230 connected to system inlet 102, a dispersion chamber 220 connected to buffer chamber 230, a reaction chamber 210 connected to dispersion chamber 220, and a system outlet 104 connected to reaction chamber 210. In one embodiment, processing system 100 further includes an array of one or more power jet modules 240A, 240B, 240C, 240D, etc. for ejecting a liquid mixture into one or more streams of droplets and pushing the one or more streams of droplets into processing system 100. The processing system further includes a reaction chamber for processing the one or more streams of droplets and the one or more gases into particulate material.

[0028] The liquid mixture is prepared from two or more precursor compounds and is then converted into droplets, each droplet having two or more precursors that are uniformly distributed together. Next, the moisture in the liquid mixture is removed as the droplets pass through dispersion chamber 220, and a gas stream is used to transport vapor into the dispersion chamber over an appropriate residence time. Further, it is 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 a system inlet 102 for delivering one or more gases from one or more gas sources into a plurality of 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 a 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 part of the dispersion chamber and can use pneumatic pressure to eject the liquid mixture and directly convert it into a vapor containing small-diameter 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 mixing compound, the temperature of the dispersion chamber, the gas flow rate, and the residence time inside the dispersion chamber, an appropriate droplet diameter can be adjusted. As an example, a vapor with a liquid droplet diameter of 0.1 micron to 1 millimeter is generated inside the dispersion chamber.

[0031] In one example, the power jet module 240A is coupled to a part of the dispersion chamber 220 and directly generates a vapor of the liquid mixture (e.g., a large number of small droplet diameters) inside the dispersion chamber. Generally, the power jet module 240A can generate a vapor of droplets with a uniform diameter. In one embodiment, the 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 are for dispersing the plurality of uniform gas streams, and one or more droplet streams are ejected from each other from the arrangement of the one or more power jet modules 240A, 240B, and 240C.

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

[0033] FIG. 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 for generating particulate materials. In one embodiment, the processing system 100 further includes a gas distributor 232 attached to the chamber wall 238 of the buffer chamber 230, channels of the distributor 232 for delivering one or more gases F1 inside the processing system into a plurality of uniform gas flows F2, a dispersion chamber 220, and one or more power jet modules 240A and 240B attached to the 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, flow at a constant rate through the channels 234 of the gas distributor 232, exit the channels 234 and flow into a plurality of uniform gas flows F2, and further flow into the dispersion chamber 220. In one embodiment, one or more gases F1 are pumped through an air filter, any particles, droplets, or contaminants can be removed, and the gas flow rate can be adjusted by a valve or other means. In one embodiment, the flow rate of the plurality of uniform gas flows F2 exiting the channels 234 is greater than the flow rate of one or more gases F1. Further, the gas converges and coalesces in the direction of the plurality of uniform gas flows F2.

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

[0036] In one embodiment, the liquid droplet stream F ejected into the dispersion chamber 220 A and the plurality of uniform gas streams F2 are dispersed at a dispersion angle α with respect to each other A to form a gas-liquid mixture F3 including the plurality of uniform gas streams F2 and the liquid droplet stream F A Further, the liquid droplet stream F ejected into the dispersion chamber 220 B and the plurality of uniform gas streams F2 are dispersed at a dispersion angle α with respect to each other B to form a gas-liquid mixture F3 including the plurality of uniform gas streams F2 and the liquid droplet stream F 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, the gases are mixed with the liquid droplet stream, and moisture is removed from the liquid droplet stream. It is designed to obtain spherical solid particles from the completely mixed liquid mixture among two or more liquid mixtures after drying the vapor of the liquid mixture. In contrast, conventional solid manufacturing processes involve mixing or grinding solid mixtures of liquid mixed compounds, resulting in non-uniform mixing of the liquid mixtures.

[0038] One or more gases can be, in particular, for example, air, oxygen, carbon dioxide, nitrogen gas, hydrogen gas, inert gas, noble gas, and combinations thereof. For example, heated air can be used as an inexpensive gas source and energy source for drying the droplet stream. The one or more gases selected can be gases that are sufficiently mixed with the droplet stream of the precursor and that dry the vapor without reacting with the precursor. In some cases, the chemicals in the droplet stream can react to some extent with one or more of the gases and / or with each other during drying, depending on the drying temperature and chemical composition of the precursor. Further, the residence time of the droplet stream of the precursor compound, which is fully mixed in the dispersion chamber, is adjustable and can be, for example, from 1 second to 1 hour, depending on the flow rate of the one or more gases and the path length through which the droplet stream needs to disperse and flow in the dispersion chamber.

[0039] In one embodiment, the processing system 100 further includes a reaction chamber 210, which is for receiving the gas-liquid mixture F3 and performing a desired reaction on the gas-liquid mixture F3 over a period of reaction time at a second temperature to produce a final reaction product F4. Finally, the final reaction product F4, which can be product particles, 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, charged cycle performance of the fine particles, etc.), particle size, morphology, crystal structure, etc. for use as a particle material.

[0040] Optionally, in one embodiment, the reaction chamber 210 is a circulating fluidized bed reactor that receives the gas-liquid mixture F3 from the dispersion chamber, mixes it with a gaseous stream of a preheated second gas, and forms the final reaction product F4 within the internal volume of the reaction chamber 210. The final reaction product F4 is heated by the thermal energy of the preheated second gas, and the complete reaction is enhanced by continuously flowing the final reaction product F4 out of the reaction chamber 210 and into a gas-solid separator coupled to the reaction chamber 210. A gas-solid separator is provided to remove by-products (and / or a portion of the reaction products) out of the system 100 via the separator outlet and recycle the solid particles back into the reaction chamber 210 via the separator outlet. Product particles with a desired diameter, crystal 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 fluidized bed reactor. A gaseous stream of a preheated second gas coming from a gas line is delivered to the reaction chamber 210, passes through a porous medium, mixes with the gas-liquid mixture F3 delivered from the dispersion chamber 220, and generates a bubbling gas-like fluid-solid mixture within the internal volume of the reaction chamber. The thermal energy of the preheated second gas heats the bubbling gas-solid mixture, and the complete reaction is enhanced by bubbling the gas-solid stream inside the reaction chamber 210. When the complete reaction occurs, the gas by-products are removed out of the reaction chamber 210 via the reactor outlet. The final reaction product F4 with a desired crystal structure, morphology, and diameter is collected and delivered out of the reaction chamber 210 via the system outlet 104.

[0042] Optionally, in another embodiment, the reaction chamber 210 is an annular fluidized bed reactor. The gaseous stream of the preheated second gas coming from the gas line is delivered to the reaction chamber 210, and also changes direction towards an additional gas stream (such as a gas stream), promoting complete mixing with the gas-liquid mixture F3 delivered from the dispersion chamber 220, and generating a uniformly mixed gas-solid mixture within the internal volume of the reaction chamber of the reactor. When the complete reaction is carried out, the gas by-products are removed from the reaction chamber 210 through the reactor outlet. Product particles with the desired crystal structure, morphology, and diameter are collected and delivered out of the reaction chamber 210 through the system outlet 104.

[0043] Optionally, in another embodiment, the reaction chamber 210 is a flash fluidized bed reactor. The reaction chamber 210 receives the gas-liquid mixture F3 from the dispersion chamber 220, mixes the gas-liquid mixture F3 with the preheated gas stream coming from the gas line, and forms a gas-solid mixture. The gas-solid mixture passes through the body of the tubular reactor coupled to the reaction chamber 210. The gas-solid mixture needs to pass through a long internal path, thereby using the thermal energy of the heating gas to promote a complete reaction. Next, the gas by-products are removed from the reaction chamber 210 through the reactor outlet, and product particles with the desired crystal structure, morphology, and diameter are collected and delivered out of the reaction chamber 210 through the system outlet 104. Note that heated air or cooled air or cooled gas or heated gas can also be delivered to the reaction chamber 210 using an additional gas line inlet.

[0044] In one embodiment, the final reaction product F4 particularly includes metal oxide materials, doped metal oxide materials, and inorganic metal salts. Examples of metal oxide materials include, but are not limited to, in particular, titanium oxide (Ti x O y , for example, Ti2O5, etc.), chromium oxide (Cr x O y , for example, Cr2O7, etc.), tin oxide (Sn x O y , for example, S n O2, SnO, SnSiO3, etc.), copper oxide (Cu x O y , for example, CuO, Cu2O, etc.), aluminum oxide (Alx O y e.g., Al2O3, etc.), manganese oxide (Mn x O y ), iron oxide (Fe x O y e.g., Fe2O3, etc.). For the mixed metal oxide material, it is desirable to adjust the composition of the final reaction product material only by the ratio of the liquid mixing compounds added to the liquid mixture added to the processing system 100. In one embodiment, a metal oxide with two or more metals (Me x Me’ y O z ) is obtained. As examples, in particular, lithium transition metal oxides (LiMeO2), lithium titanates (e.g., Li4Ti5O 12 ), lithium cobalt oxide (e.g., LiCoO2), lithium manganese oxide (e.g., LiMn2O4), lithium nickel oxide (e.g., LiNiO2), lithium iron phosphate (e.g., LiFePO4), lithium cobalt phosphate (e.g., LiCoPO4), lithium manganese phosphate (e.g., LiMnPO4), lithium nickel phosphate (e.g., LiNiPO4), sodium iron oxide (e.g., NaFe2O3), sodium iron phosphate (e.g., NaFeP2O7) are included.

[0045] In another embodiment, the final reaction product F4 includes a metal oxide with three or four interlayer metals. Examples of the metal oxide material include, but are not limited to, in particular, 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 bilayer structured 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, for example, 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 doped metals are included. As another example, in particular, 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) are included. In another example, for example, a mixed metal oxide with a doped metal is obtained. In particular, Li a (Ni x Mn y Co z )MeO b (where Me = a doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), Li a (Ni x Mn y Co z )MeO b F c (where Me = a doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C) is obtained.

[0046] In particular, other metal oxide materials containing 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) can also be obtained. Furthermore, the metal oxide material can exhibit a crystal structure of a metal in the form of a layered spinel, layered olivine, etc. Furthermore, the morphology of the final reaction product F4 exists 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 including a CPU 340 to automatically control the processing system 100. The electronic control unit 300 adjusts various processing parameters (e.g., flow rate, mixing ratio, temperature, residence time, etc.) inside 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 diameter and generation amount of one or more droplet flows generated by the power jet module can be adjusted. Furthermore, the flow rate and temperature of various gases flowing in 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 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 being connected to the dispersion chamber 230 and adapted to collect the gas-liquid mixture F3 from the dispersion chamber and separate it into the first type of solid particles and waste. Optionally, the first separator is connected to a drying chamber, the drying chamber being connected to the dispersion chamber 230, collecting the gas-liquid mixture F3 from the dispersion chamber, drying the gas-liquid mixture F3 into gas-solid particles, delivering the gas-solid particles to the first separator, and separating the gas-solid particles 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 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, the final reaction product F4 is collected and cooled by one or more separators, coolant lines, and / or heat exchangers and, once cooled, exits the system 100. The final reaction product F4 may include an oxidizing liquid mixture (such as an oxide material) suitable for packing into battery cells. Additionally, an additional pump may be installed to achieve a desired pressure gradient.

[0050] FIG. 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 of FIG. 2A is a cross-section taken along the 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 surrounded inside the 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 unified direction and at a constant flow rate.

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

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

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

[0054] In one embodiment, the power jet module 240A includes a power jet 242A for ejecting the 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 attached inside the support frame 244A AA module actuator 246A attached inside a support frame 244A for moving and pushing into the dispersion chamber 220, and a connector 245A connecting the module actuator 246A and the power jet 242A are included. Similarly, the power jet module 240B includes a power jet 242B, a support frame 244B, a module actuator 246B, and a connector 245B. Similarly, the power jet module 240C includes a power jet 242C, a support frame 244C, a module actuator 246C, and a connector 245C. Also, the power jet module 240D includes a power jet 242D, a support frame 244D, a module actuator 246D, and a 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 a liquid droplet stream of F A ~F D is injected into the dispersion chamber 220 and passes through the dispersion chamber vertically downward. Alternatively, the power jets 242A - 242D can be positioned near the bottom of the vertically positioned dispersion chamber 220, injecting the liquid droplet stream upward into the dispersion chamber (which can be shown as in FIG. 3B), making it possible to increase 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 horizontally positioned and the power jets 242A - 242D are positioned near one end of the dispersion chamber 220, as a result, a vapor stream delivered from one end of the dispersion chamber 220 through to the other end can pass through the internal path of the dispersion chamber 220 over the length of its residence time.

[0056] In addition to the liquid mixture stream, the dispersion chamber 220 is also filled with a gas stream. The gas distributor 232 is coupled to the end of the buffer chamber and is adapted to flow a plurality of integrated gases F2 into the dispersion chamber 220. Simultaneously with the formation of the droplet stream inside the dispersion chamber 220 for the droplet stream to be conveyed through the dispersion chamber 220, the gas stream of the plurality of integrated gases F2 that can be delivered to the dispersion chamber 220 may or may not remove moisture from the vapor, and forms a gas-liquid mixture in the direction of F3 containing the liquid mixture. Also, the gas stream of the plurality of integrated gases F2 is delivered to the dispersion chamber 220 before the vapor is formed, fills the internal volume of the dispersion chamber 220, and can be preheated to a first temperature before the droplet stream occurs inside the dispersion chamber 220.

[0057] In one example, the gas distributor 232 is connected to the end of the buffer chamber 230, the end of the buffer chamber 230 is connected to the upper part of the dispersion chamber 310, the gas distributor 232 delivers a plurality of integrated gases F2 to the dispersion chamber 220, and the droplet stream generated by the power jet module attached to the chamber wall 228 of the dispersion chamber 220 is mixed with the gas F2. In one embodiment, the plurality of integrated 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, by using the plurality of integrated gases F2 without preheating, it is ensured that the gas-liquid mixture formed inside the dispersion chamber 220 is uniformly mixed with the gas.

[0058] FIG. 2D shows the dispersion angles of the plurality of integrated gases F2 and the droplet stream FA inside the dispersion chamber 220 configured in the processing system 100 of FIG. 1 according to an embodiment of the present invention.

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

[0060] In one embodiment, the liquid flow of the droplet flow of a liquid mixture (e.g., droplet flow F A ), and the gas flow of a gas (e.g., a plurality of integrated gases F2) can collide with each other inside the dispersion chamber at an angle of 0 degrees to 180 degrees. Further, the liquid flow F of the droplet flow A and the air flow of the gas flow F2 can flow linearly, spirally, intertwined, and / or in other states.

[0061] In one embodiment, the droplet flow F A and the plurality of integrated gases F2 are at an angle α A (0 ≤ α A ≤ 180 degrees), and can merge and mix inside the dispersion chamber (e.g., become co-current). Further, the liquid flow F of the droplet flow A and the plurality of integrated gases F2 flow at various angles facing each other and / or at various angles toward the outer periphery of the chamber body, and inside the dispersion chamber 220, can flow spirally, intertwined, and / or promote the formation of other air flows. In one embodiment, the droplet flow and the gas flow are configured at an angle α less than 90 degrees and can merge and mix inside the dispersion chamber. In another embodiment, the liquid flow F of the droplet flow A and the gas flow F2 are configured at an angle α of 90 degrees and can merge and mix inside the dispersion chamber. Further, the liquid flow F of the droplet flow A and the gas flow F2 flow at various angles facing each other and / or at various angles toward the outer periphery of the chamber body, and inside the dispersion chamber 220, can flow spirally, intertwined, and / or promote the formation of other air flows.

[0062] For example, as shown in the example of FIG. 3B, the gas flow and the liquid flow of the droplet flow flowing inside the dispersion chamber can be configured to flow as co-current. The advantages of co-current are, in particular, that the residence time is short, the particle drying temperature is low, and the particle separation efficiency is high. In another embodiment, similarly as shown in the example of FIG. 3B, the gas flow of the plurality of integrated gas flows and the liquid flow of the droplet flow flowing inside the dispersion chamber can be configured to flow as counter-current. The advantages of counter-current are, in particular, that the residence time is long and the particle drying temperature is high.

[0063] In another embodiment, the liquid flow F of the droplet flow A and the gas flow F2 are configured at an angle α of 180 degrees and flow like convection. In an alternative embodiment, the dispersion chamber 220 can be positioned horizontally. Similarly, the liquid flow F of the droplet flow A and the gas flow F2 can be configured at an angle α of 0 to 180 degrees. Referring also to FIG. 1, once the droplet flow of the liquid mixture is formed into a gas-liquid mixture with gas, the gas-liquid mixture is delivered through the dispersion chamber 220 to the reaction chamber 210.

[0064] FIG. 2F is a perspective view of a power jet according to an 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 an electronic control unit 300 for instructing 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 inside 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, continuously at a desired delivery rate (e.g., an amount adjusted by a throttle valve or other means) to achieve a 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 from the power jet 242A is delivered to the dispersion chamber 220 through the chamber inlet.

[0066] In one embodiment, the power jet 242A has a cuboid structure with six rectangular faces that are perpendicular to each other. Further, on one side surface of the power jet 242A, there is a nozzle row 480A. In one embodiment, the nozzle row 480A is on the side surface of the power jet 242A where the bottom width is shorter than the side length, and consists of 3×10 orifices 402A evenly installed, forming a rectangular shape. In another embodiment, the nozzle row 480A consists of a different pattern of orifices.

[0067] In another embodiment, the power jet has a different shape and structure, for example, a horizontal parallel plane and a cylinder structure with a circular or elliptical cross-section. Further, on one side of the horizontal parallel plane of the power jet, there is a nozzle row. In one embodiment, the nozzle row consists of a single orifice.

[0068] FIG. 3 shows in perspective view an example of a power jet module configured in the dispersion chamber of the processing system. In one embodiment, a power jet module 240A for ejecting a liquid mixture into one or more droplet streams and pushing the one or more droplet streams into the processing system includes a power jet 242A for ejecting the 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 movement of the power jet 242A, a first module actuator 246A for moving the power jet connected to coincide 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] Also, as shown in FIG. 3, the dispersion chamber 220 includes one or more openings 222A, 222B, 222C, 222D, 222E, and 222F, which are positioned on the chamber wall of the dispersion chamber 220 and adapted to connect and fit to the power jet of the power jet module on one side of the power jet with the nozzle row. In one embodiment, the shape and arrangement of the one or more openings are shown in FIG. 3, and the one or more openings are rectangles with a bottom width shorter than the side length and are positioned equidistantly adjacent to each other on the same horizontal line of the chamber wall.

[0070] Also, as shown in FIG. 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, in order to convey a droplet stream through the dispersion chamber 220, inside the dispersion chamber 220, simultaneously with the formation of the droplet stream ejected from the power jet of the power jet module, the plurality of integrated gases F2 that can be delivered to the dispersion chamber 220 may or may not be able to remove moisture from the vapor, and form a gas-liquid mixture containing a liquid mixture and a plurality of integrated gases in the direction of F3. Also, the gas flow of the plurality of integrated gases F2 is delivered to the dispersion chamber 220 before the droplet stream is formed, fills the internal volume of the dispersion chamber 220 before the droplet stream is generated inside the dispersion chamber 220, and optionally can be preheated to a first temperature.

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

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

[0073] In one embodiment of the present invention, the directions of the plurality of uniform gas streams F2 delivered to the dispersion chamber are parallel to the chamber wall of the dispersion chamber 220. And the direction of the gas-liquid mixture F3 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 directions of the plurality of uniform gas streams 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] FIG. 4 shows a perspective view of 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 pushing the one or more droplet streams into the processing system includes a power jet 442A for ejecting the 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 the movement of the power jet 442A, a first module actuator 446A for moving the power jet connected to coincide 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 pushing the one or more droplet streams into the processing system includes a power jet 442G for ejecting the 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 the movement of the power jet 442G, a first module actuator 446G for moving the power jet connected to coincide 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] Also, as shown in FIG. 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 on the chamber wall of the dispersion chamber 420 and are adapted to connect and mate with the power jet of the power jet module on one side of the power jet with a nozzle array. In one embodiment, the shape of the one or more openings is shown in FIG. 4, and the one or more openings are rectangles with a bottom width shorter than the side length. In one embodiment, the arrangement of the one or more openings is further shown in FIG. 4, and the openings 422A - 422F are equally spaced and adjacent to each other on the same horizontal line of the chamber wall of the first row, and the openings 422G - 422L are equally spaced and adjacent to each other on the same horizontal line of the chamber wall in a second row different from the first row. Further, each of the openings 422A - 422L is not positioned on the same vertical line of the chamber wall so as not to overlap each other.

[0076] Also, as shown in FIG. 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, in order to convey a droplet flow through the dispersion chamber 420, inside the dispersion chamber 420, simultaneously with the formation of the droplet flow ejected from the power jet of the power jet module, the plurality of integrated gases F2 that can be delivered to the dispersion chamber 420 may or may not be able to remove moisture from the vapor, and form a gas - liquid mixture containing a liquid mixture and the plurality of integrated gases in the direction of F3. Also, the gas flow of the plurality of integrated gases F2 is delivered to the dispersion chamber 420 before the droplet flow is formed, fills the internal volume of the dispersion chamber 420 before the droplet flow occurs inside the dispersion chamber 420, and optionally can be pre - heated to a first temperature.

[0077] In one embodiment, one or more of the 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 and adapted to a power jet module to inject a droplet stream into the dispersion chamber 420 and pass vertically downward through the dispersion chamber. Further, in the same embodiment, one or more of the openings 422G - 422L are positioned near the bottom surface of the dispersion chamber 420. In another embodiment, when the dispersion chamber 420 (e.g., a tubular dispersion chamber, etc.) is horizontally positioned and one or more of the openings 422A - 422F are positioned near one end of the dispersion chamber 420, as a result, these openings are adapted and connected to a power jet module that injects a droplet stream delivered from one end of the dispersion chamber 420 to the other end, and the droplet stream can pass through the internal path of the dispersion chamber 420 over the length of its residence time. Further, in the same embodiment, one or more of the openings 422G - 422L are positioned near the other end of the dispersion chamber 420.

[0078] Further, in one embodiment, the droplet stream ejected into the dispersion chamber 420 is dispersed together with a plurality of uniform gas streams F2, resulting in a gas - liquid mixture F3 that includes the plurality of uniform gas streams F2 and the droplet stream. 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 plurality of uniform gas streams F2 delivered to the dispersion chamber 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 plurality of uniform gas streams 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] FIG. 5 shows 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 pushing the one or more droplet streams into the processing system includes a power jet 542A for ejecting the 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 the movement of the power jet 542A, a first module actuator 546A for moving the power jet connected to coincide 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] Also, as shown in FIG. 5, the dispersion chamber 520 includes one or more openings 522A, 522B, 522C, 522D, 522E, and 522F, which are positioned on the chamber wall of the dispersion chamber 520 and adapted to connect and conform to the power jet of the power jet module on one side of the power jet, with a nozzle row and a bottom width longer than its side length. In one embodiment, the shape and arrangement of the one or more openings are shown in FIG. 5, and the one or more openings are rectangles with a bottom width longer than the side length and are equally spaced adjacent to each other 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 a horizontally - positioned dispersion chamber 520 (e.g., a tubular dispersion chamber, etc.), inject a droplet stream into the dispersion chamber 520, and are connected and adapted to a power jet module to pass 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, and are connected and adapted to a power jet module to inject the 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 plurality of 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 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 plurality of uniform gas streams 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 plurality of 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 plurality of uniform gas streams F2 into the droplet stream from the power jet delivered through the dispersion chamber 520 is also parallel to the chamber wall of the dispersion chamber 520.

[0085] FIG. 6 shows 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 pushing the one or more droplet streams into the processing system includes a power jet 642A for ejecting the 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 the movement of the power jet 642A, a first module actuator 646A for moving the power jet connected to coincide 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] Also, as shown in FIG. 6, the dispersion chamber 620 includes one or more openings 622A, 622B, 622C, which are positioned on the chamber wall of the dispersion chamber 620 and adapted to connect and conform to a power jet of the power jet module on one side of the power jet with a nozzle row. In one embodiment, the shape and arrangement of the one or more openings are shown in FIG. 6, and the one or more openings are rectangles with a bottom width longer than the side length and are positioned equidistantly adjacent to each other on the same horizontal line of the chamber wall.

[0087] Also, as shown in FIG. 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, in order to convey a droplet stream through the dispersion chamber 620, inside the dispersion chamber 620, simultaneously with the formation of the droplet stream ejected from the power jet of the power jet module, the plurality of integrated gases F2 that can be delivered to the dispersion chamber 620 may or may not be able to remove moisture from the vapor, and form a gas-liquid mixture including a liquid mixture and the plurality of integrated gases in the direction of F3. Also, the gas stream of the plurality of integrated gases F2 is delivered to the dispersion chamber 620 before the droplet stream is formed, fills the internal volume of the dispersion chamber 620 before the droplet stream is generated inside the dispersion chamber 620, and optionally can be preheated to a first temperature.

[0088] In one embodiment, one or more openings 622A - 622C are positioned near the top of the vertically positioned dispersion chamber 620 (e.g., a dome-shaped dispersion chamber, etc.), inject a droplet stream into the dispersion chamber 620, and are connected and adapted to a power jet module to pass vertically downward through the dispersion chamber. Alternatively, one or more openings 622A - 622C can be positioned near the bottom surface of the vertically positioned dispersion chamber 620, and are connected and adapted to a power jet module to inject the droplet stream upward into the dispersion chamber by increasing the residence time of the liquid flow generated inside the dispersion chamber. In another embodiment, when the dispersion chamber 620 (e.g., a tubular dispersion chamber, etc.) is horizontally positioned and one or more openings 622A - 622C are positioned near one end of the dispersion chamber 620, as a result, these openings are adapted and connected to a power jet module that injects a droplet stream delivered from one end of the dispersion chamber 620 through to the other end, and the droplet stream can pass through the path inside the dispersion chamber 620 over 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 directions of the plurality of uniform gas flows F2 delivered to the dispersion chamber are parallel to the chamber wall of the dispersion chamber 620. And the direction of the gas-liquid mixture F3 formed by dispersing the plurality of uniform gas flows F2 from the power jet delivered through the dispersion chamber 620 into the droplet flow is also parallel to the chamber wall of the dispersion chamber 620.

[0090] FIG. 7A is a front view of an exemplary power jet module adapted to be coupled to the dispersion chamber. The power jet module is sealed at the opening of the chamber wall 228 of the dispersion chamber by the sealing element 249A of the power jet module 240A, and the power jet of the power jet module is positioned at a first position where the power jet 242A is positioned so as to be connected to the opening of the dispersion chamber. In one embodiment, the power jet 242A is capable of ejecting one or more droplet flows F A into the dispersion chamber under the control of the electronic control center.

[0091] Referring also to FIG. 3, the power jet module further includes a support frame 244A for supporting the 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, and the cleaning assembly includes a movable cleaning blade element 252A moved by the third module actuator 250A and a movable suction element 254A.

[0092] In one embodiment, the first module actuator 246A is controlled by an electronic control center and moves the connector 245A connecting the first module actuator 246A and the power jet 242A along the "H" direction perpendicular to the chamber wall of the dispersion chamber, thereby adapting to move the power jet. When moved by the first module actuator 246A along the "H" direction towards the opening on the dispersion chamber, at the same time, the connector 245A moves the power jet 242A along the "H" direction towards the opening on the dispersion chamber. When moved by the first module actuator 246A along the "H" direction away from the opening on the dispersion chamber, at the same time, the connector 245A moves the power jet 242A along the "H" direction away from the opening on the dispersion chamber. When the power jet 242A moves and connects to coincide with the opening on the dispersion chamber, it reaches the first position of the power jet 242A.

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

[0094] FIG. 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 the opening of the chamber wall 228 of the dispersion chamber by the sealing element 249A of the power jet module 240A, and the power jet of the power jet module is positioned at a second position where the power jet 242A of the power jet module 240A is positioned away from the opening of the dispersion chamber. In one embodiment, the power jet 242A does not eject one or more droplet streams F A into the dispersion chamber at the second position under the control of the electronic control center.

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

[0096] In one embodiment, referring also to FIG. 7A, 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 chamber wall of the dispersion chamber. When the power jet 242A moves away from the opening on the dispersion chamber, it reaches a second position of the power jet 242A.

[0097] In one embodiment, referring also to FIG. 7A, the second module actuator 248A is adapted to move the door 247A along the direction of "V1" parallel to the chamber wall of the dispersion chamber. When the door 247A moves to a closed position to shield the power jet 242A from passing through the door 247A, the power jet 242A reaches a second position.

[0098] Figure 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 has a cleaning assembly of the power jet module 240A for cleaning the power jet of the power jet module. As shown in Figure 7C, the power jet module 240A further includes a cleaning assembly, and the cleaning assembly includes a movable cleaning blade element 252A that is moved by a third module actuator 250A along a direction of "V2" and a movable suction element 254A.

[0099] In one embodiment, the third module actuator 250A moves the cleaning blade element 252A along a direction of V2 parallel to a surface with an array of one or more nozzle orifices of the power jet 242A and is adapted to clean the surface with the cleaning blade element 252A, where the power jet 252A is in a second position positioned away from the opening in 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 Figure 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 with a power jet module coupled to a dispersion chamber for producing a product from a liquid mixture Figure 8 shows the steps of a method 800 of operating a system with a power jet module coupled to a dispersion chamber. Method 800 includes step 810, step 820, step 830, step 840, step 850, step 860, and step 870.

[0101] Step 810 of method 800 includes moving one or more power jet modules in a first direction to a jet 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 a liquid mixture through one or more power jets of the one or more power jet modules to form one or more droplet streams.

[0102] In one embodiment, the liquid mixture is formed from two or more precursors. Generally, a liquid precursor compound can be prepared directly to be the liquid mixture at a desired concentration. A solid precursor compound can be decomposed 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, the desired molar ratio of two or more solid precursors can be prepared to be the liquid mixture, such as by measuring appropriate amounts of the two or more solid precursors and formulating them in a container with an appropriate amount of solvent. Depending on the solubility of the precursor in the solvent, the pH, temperature, and mechanical agitation and mixing can be adjusted to obtain the liquid mixture, fully decomposing and / or evenly dispersing the precursor compound.

[0103] In one example, to obtain a final reaction product of a mixed metal oxide material, two or more metal-containing precursors are mixed to form a liquid mixture. Examples of metal-containing precursors include, but are not limited to, in particular, metal salts, lithium-containing compounds, cobalt-containing compounds, manganese-containing compounds, nickel-containing compounds, lithium sulfate (Li2SO4), lithium nitrate (LiNO3), lithium carbonate (Li2CO3), lithium acetate (LiCH2COO), lithium hydroxide (LiOH), lithium formate (LiCHO2), lithium chloride (LiCl), cobalt sulfate (CoSO4), cobalt nitrate (Co(NO3)2), cobalt carbonate (CoCO3), cobalt acetate (Co(CH2COO)2), cobalt hydroxide (Co(OH)2), cobalt formate (Co(CHO2)2), cobalt chloride (CoCl2), manganese sulfate (MnSO4), manganese nitrate (Mn(NO3)2), manganese carbonate (MnCO3), manganese acetate (Mn(CH2COO)2), manganese hydroxide (Mn(OH)2), manganese formate (Mn(CHO2)2), manganese chloride (MnCl2), nickel sulfate (NiSO4), nickel nitrate (Ni(NO3)2), nickel carbonate (NiCO3), nickel acetate (Ni(CH2COO)2), nickel hydroxide (Ni(OH)2), nickel formate (Ni(CHO2)2), nickel chloride (NiCl2), 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] Rather than being bound by theory, in order to prepare an oxide material involving two or more different metals, it is contemplated to use two or more metal-containing precursor compounds as sources of each metal element and first mix all of the required metal elements to form a liquid mixture (e.g., a solution, slurry, or gel mixture), such that two or more different metals can be uniformly mixed in a desired ratio. As an example, one or more highly water-soluble metal salts can be used to prepare an aqueous solution, slurry, or gel liquid mixture. For example, metal nitrates, metal sulfates, metal chlorides, metal acetates, metal formates can be used. Organic solvents (e.g., alcohols, isopropanol, etc.) can be used to decompose or disperse low water-soluble metal-containing precursors. Optionally, the pH value of the liquid mixture can be adjusted to increase the solubility of one or more precursor compounds. Optionally, chemical additives, gelling agents, and surfactants (e.g., ammonia, EDTA, etc.) can be added to the liquid mixture to facilitate the decomposition or dispersion of the precursor compounds in the selected solvent.

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

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

[0107] In the method 800 of generating particle materials without being bound by theory, two or more precursor compounds are prepared to form a liquid mixture, which is then converted into droplets, and each droplet has two or more precursors that are uniformly distributed together. Next, the moisture in the liquid mixture is removed as the droplets pass through the dispersion chamber, and a gas stream of a first gas is used to transport the vapor into the dispersion chamber over an appropriate residence time. Furthermore, it is envisioned that by adjusting the concentration of the precursor compounds in the liquid mixture and the droplet diameter of the vapor of the liquid mixture, the chemical composition, particle size, and particle size distribution of the final product particles of the battery material can be regulated.

[0108] In one embodiment, one or more droplet streams are dispersed into the dispersion chamber over a desired first residence time at a first temperature, and the moisture therein is removed. When the dispersion of moisture from one or more droplet streams of the precursor compounds occurs in a dispersion chamber filled with a gas stream, a gas-liquid mixture composed of a heated first gas and the liquid mixture is formed. Thus, in one embodiment of the present invention, the gas stream flowing in the dispersion chamber is provided to be used as a gas source for forming a gas-liquid mixture in the dispersion chamber. In another embodiment, the gas flowing in the dispersion chamber is heated, and the thermal energy of the heated gas stream 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 of 70°C to 600°C by passing through an appropriate heating mechanism such as an electric heater or a fuel combustion 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 (for example, heating the chamber body of the dispersion chamber, etc.). The advantages of using a heated gas include, in particular, fast heat transfer, high temperature uniformity, and easy enhancement of functionality. The dispersion chamber can be any chamber such as a dome-shaped ceramic dispersion chamber, a quartz chamber, a tubular chamber, or a heating furnace with a surrounding chamber body. Optionally, the chamber body is made of a heat insulating material (for example, ceramic, etc.) to prevent heat loss during drying.

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

[0111] Step 840 of method 800 includes processing one or more droplet streams inside the reaction chamber of the 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. Further, the reaction chamber can be any of a rotary furnace, a stirred furnace, a heating furnace with multiple temperature zones, etc., and a furnace type reactor of combinations thereof.

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

[0113] In one embodiment, it is contemplated to use the energy from a second gas stream heated to the reaction temperature to obtain a certain type of solid particles from the reaction of the droplet stream in the reaction chamber, to make the reaction sufficiently complete, and to obtain the desired crystal structure of the final reaction product. As advantages of flowing already heated air or gas, in particular, fast heat transfer, a uniform temperature distribution (especially in the high temperature region), and easy enhancement of functionality are brought about. 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 the oxidation reaction inside the reaction chamber, an oxidizing gas can be used as the second gas stream. For the reduction reaction 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, etc.) is delivered out of the reaction chamber, and the reaction product is cooled to obtain final solid particles of a desired diameter, morphology, and crystal structure, and can be immediately used for battery utilization. For example, the reaction product can be slowly cooled to room temperature to avoid hindering or failing the process of forming its stable energy state with a uniform morphology and the desired crystal structure.

[0115] Step 850 of method 800 includes closing one or more doors of the power jet module. Step 860 of method 800 includes moving one or more power jet modules in a second direction to a stop position. Optionally, after step 860, step 810 of method 800 is performed. Step 870 of method 800 includes moving one or more power jet modules in a third direction and positioning one or more power jet modules at an operating position. Optionally, after step 870, step 810 of method 800 is performed.

[0116] FIG. 9 shows the steps of a method 900 for operating a system with a power jet module. Method 900 includes step 910, step 920, step 930, and step 940.

[0117] Step 910 of method 900 includes moving one or more power jet modules in a first direction so as to be at an ejection position. Step 920 of method 900 includes moving one or more power jet modules in a second direction so as to be at a stop position. Step 930 of method 900 includes moving one or more power jet modules in a third direction and positioning one or more power jet modules at an operating position. Step 940 of method 900 includes cleaning one or more power jets using one or more cleaning assemblies and removing accumulated unwanted materials and contaminants. Optionally, after step 940 of method 900, any of steps 910, 920, or 930 can be performed.

[0118] The foregoing description is directed to embodiments of the invention, and other and further embodiments of the invention may be devised without departing from the basic scope thereof, which is determined by the claims that follow.

Claims

1. A method for manufacturing one or more metal-containing battery materials for a battery cell using a liquid mixture, comprising: one or more power jet modules; a dispersion chamber having one or more openings coupled to the one or more power jet modules; a reaction chamber connected to the dispersion chamber; providing a processing system including; each of the one or more power jet modules includes one or more doors and a power jet including an array of two or more nozzle orifices on one side, each orifice being adapted to eject a liquid mixture into one or more streams of droplets; moving the one or more power jet modules in a first direction to an ejection position; opening one or more doors of the one or more power jet modules; ejecting, by the one or more power jets of the one or more power jet modules, a liquid mixture including a lithium-containing compound and one or more metal-containing compounds into one or more streams of droplets; processing the one or more streams of droplets into the one or more metal-containing battery materials inside a reaction chamber of the processing system.

2. The manufacturing method according to claim 1, further comprising closing one or more doors of the one or more power jet modules.

3. The manufacturing method according to claim 1, further comprising moving the one or more power jet modules in a second direction to a stop position.

4. The manufacturing method according to claim 1, further comprising moving the one or more power jet modules in a third direction to an operating position.

5. The manufacturing method according to claim 1, further comprising cleaning the one or more power jets using one or more cleaning assemblies to remove accumulated unwanted materials and contaminants.

6. The manufacturing method according to claim 1, further comprising dispersing, inside the dispersion chamber, one or more uniform gas streams together with the one or more streams of droplets at a dispersion angle (α) in the range of 0 to 180 degrees.

7. The manufacturing method according to claim 1, further comprising forming a gas-liquid mixture including one or more uniform gas streams and the one or more streams of droplets.

8. The manufacturing method according to claim 7, further comprising drying the gas-liquid mixture at a first temperature to obtain the one or more metal-containing battery materials.

9. The manufacturing method according to claim 1, further comprising the step of annealing the one or more metal-containing battery materials at a second temperature for a reaction time to obtain a final reaction product having a desired crystal structure.

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

11. The manufacturing method according to claim 1, wherein the dispersion chamber is positioned vertically.

12. The manufacturing method according to claim 1, wherein the dispersion chamber is positioned horizontally.

13. The metal-containing battery material is selected from the group consisting of lithium nickel cobalt oxide, lithium nickel manganese oxide, lithium nickel manganese cobalt oxide, lithium cobalt aluminum oxide, lithium nickel cobalt aluminum oxide, sodium iron manganese oxide, mixed metal oxides with doped metals, and combinations thereof, according to the manufacturing method of claim 1.

14. The manufacturing method according to claim 1, further comprising the step of aligning each of the one or more power jet modules with one or more openings of the dispersion chamber.

15. The manufacturing method according to claim 1, further comprising the step of coupling each door of the one or more power jet modules so as to be connected to one or more openings of the dispersion chamber.

16. A method for manufacturing one or more metal-containing battery materials for a battery cell using a liquid mixture, one or more power jet modules, a dispersion chamber having one or more openings coupled to the one or more power jet modules, a reaction chamber connected to the dispersion chamber, providing a processing system including, each of the one or more power jet modules includes one or more doors and a power jet including an array of two or more nozzle orifices on one side, and each orifice is adapted to eject a liquid mixture into one or more droplet streams, moving the one or more power jet modules in a first direction to an ejection position, opening one or more doors of the one or more power jet modules, ejecting a liquid mixture including a lithium-containing compound and one or more metal-containing compounds into one or more droplet streams by one or more power jets of the one or more power jet modules, Dispersing one or more uniform gas flows together with the one or more droplet flows at a dispersion angle (α) in the range of 0 to 180 degrees inside the dispersion chamber; Forming a gas-liquid mixture comprising one or more uniform gas flows and the one or more droplet flows; Treating the gas-liquid mixture with the one or more metal-containing battery materials inside a reaction chamber of a processing system. A manufacturing method characterized by comprising the steps.

17. The manufacturing method according to claim 16, wherein the dispersion chamber is vertically positioned.

18. The manufacturing method according to claim 16, wherein the dispersion chamber is horizontally positioned.

19. A method for manufacturing a metal-containing battery material for a battery cell using a liquid mixture, One or more power jet modules; A dispersion chamber having one or more openings coupled to the one or more power jet modules; A reaction chamber connected to the dispersion chamber; Providing a processing system including, Each of the one or more power jet modules comprises one or more doors and a power jet including an array of two or more nozzle orifices on one side, each orifice being adapted to eject a liquid mixture into one or more droplet flows; Moving the one or more power jet modules in a first direction to an ejection position; Opening one or more doors of the one or more power jet modules; Ejecting a liquid mixture comprising a lithium-containing compound and one or more metal-containing compounds by one or more power jets of the one or more power jet modules into one or more droplet flows; Dispersing one or more uniform gas flows together with the one or more droplet flows at a dispersion angle (α) in the range of 0 to 180 degrees inside the dispersion chamber; Forming a gas-liquid mixture comprising one or more uniform gas flows and the one or more droplet flows; Drying the gas-liquid mixture at a first temperature to obtain one or more solid materials; Annealing the one or more solid materials at a second temperature for a reaction time to form one or more particles of the metal-containing battery material having a desired crystal structure. A manufacturing method characterized by comprising the steps.

20. The metal-containing battery material is selected from the group consisting of lithium nickel cobalt oxide, lithium nickel manganese oxide, lithium nickel manganese cobalt oxide, lithium cobalt aluminum oxide, lithium nickel cobalt aluminum oxide, sodium iron manganese oxide, mixed metal oxides with doped metals, and combinations thereof, according to the manufacturing method described in claim 19.

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