A method of manufacturing a mixed metal oxide powder is provided. The method includes steps of mixing two or more metal precursors in a solvent to form a dispersion of the metal precursors in the solvent; drying the dispersion to obtain a dried mixed metal precursor powder; jet milling the dried mixed metal precursor powder to obtain particles having a size distribution in a range of 0.2-20 micrometers; and exposing the particles to a hydrocarbon flame or oxygen plasma to provide the mixed metal oxide powder. Mixed metal oxide powders produced by the disclosed methods are also provided.

A continuous process for producing a material of a battery cell using a system having a mist generator, a drying chamber, one or more gas-solid separators and a reactor is provided. A mist generated from a liquid mixture of two or more metal precursor compounds in desired ratio is dried inside the drying chamber. Heated air or gas is served as the gas source for forming various gas-solid mixtures and as the energy source for reactions inside the drying chamber and the reactor. One or more gas-solid separators are used in the system to separate gas-solid mixtures from the drying chamber into solid particles mixed with the metal precursor compounds and continuously deliver the solid particles into the reactor for further reaction to obtain final solid material particles with desired crystal structure, particle size, and morphology.

A continuous process for producing a material of a battery cell using a system having a mist generator, a drying chamber, one or more gas-solid separators and a reactor is provided. A mist generated from a liquid mixture of two or more metal precursor compounds in desired ratio is dried inside the drying chamber. Heated air or gas is served as the gas source for forming various gas-solid mixtures and as the energy source for reactions inside the drying chamber and the reactor. One or more gas-solid separators are used in the system to separate gas-solid mixtures from the drying chamber into solid particles mixed with the metal precursor compounds and continuously deliver the solid particles into the reactor for further reaction to obtain final solid material particles with desired crystal structure, particle size, and morphology.

A system and method thereof are provided for multi-stage processing of one or more precursor compounds into a battery material. The system includes a mist generator, a drying chamber, one or more gas-solid separators, and one or more in-line reaction modules comprised of one or more gas-solid feeders, one or more gas-solid separators, and one or more reactors. Various gas-solid mixtures are formed within the internal plenums of the drying chamber, the gas-solid feeders, and the reactors. In addition, heated air or gas is served as the energy source within the processing system and as the gas source for forming the gas-solid mixtures to facilitate reaction rate and uniformity of the reactions therein. Precursor compounds are continuously delivered into the processing system and processed in-line through the internal plenums of the drying chamber and the reaction modules into final reaction particles useful as a battery material.

A system and method thereof are provided for multi-stage processing of one or more precursor compounds into a battery material. The system includes a mist generator, a drying chamber, one or more gas-solid separators, and one or more in-line reaction modules comprised of one or more gas-solid feeders, one or more gas-solid separators, and one or more reactors. Various gas-solid mixtures are formed within the internal plenums of the drying chamber, the gas-solid feeders, and the reactors. In addition, heated air or gas is served as the energy source within the processing system and as the gas source for forming the gas-solid mixtures to facilitate reaction rate and uniformity of the reactions therein. Precursor compounds are continuously delivered into the processing system and processed in-line through the internal plenums of the drying chamber and the reaction modules into final reaction particles useful as a battery material.

Methods for preparation of surfactant-free ultra-small spinel ternary metal oxide nanoparticles are provided. A method comprises dissolving first and second metal salts in deionized water in a specific mole ratio to form a solution comprising two different metal ions, applying a coprecipitation method and adding an alkaline solution to the solution to form a colloidal suspension, wherein a colloid of the colloidal suspension is a metal hydroxide, adjusting the amount and the addition rate of the alkaline solution to form a specific structure of metal hydroxide precipitate; washing and drying the metal hydroxide to form a structured metal hydroxide powder, and applying a calcination method to the structured metal hydroxide powder to form a surfactant-free spinel-type (AB.sub.2O.sub.4) ternary metal oxide, wherein A and B each respectively comprise a metal element.

Methods for preparation of surfactant-free ultra-small spinel ternary metal oxide nanoparticles are provided. A method comprises dissolving first and second metal salts in deionized water in a specific mole ratio to form a solution comprising two different metal ions, applying a coprecipitation method and adding an alkaline solution to the solution to form a colloidal suspension, wherein a colloid of the colloidal suspension is a metal hydroxide, adjusting the amount and the addition rate of the alkaline solution to form a specific structure of metal hydroxide precipitate; washing and drying the metal hydroxide to form a structured metal hydroxide powder, and applying a calcination method to the structured metal hydroxide powder to form a surfactant-free spinel-type (AB.sub.2O.sub.4) ternary metal oxide, wherein A and B each respectively comprise a metal element.

The method of fabricating metal oxide nanomaterials using a thermally decomposable substrate can include combining an aqueous solution including a metal salt with a thermally decomposable solid substrate. In an embodiment, the aqueous solution can be nebulized and applied directly on the solid substrate. In an embodiment, the solid substrate can be macerated in the aqueous solution. The solid material, once combined with the aqueous solution, can then be calcined at a temperature ranging from about 400° C. to about 900° C. Calcination produces metal oxide nanoparticles and transforms the solid material into capping substrate molecules that are separated by the metal oxide ions. Thus, the metal oxide nanomaterials include capping substrate molecules separated by metal oxide nanoparticles. The present method reverses the conventional capping process by placing the metal oxide ions between the molecules of the capping substrate, which stay in place (keeping distance between ions), even during calcination.

The method of fabricating metal oxide nanomaterials using a thermally decomposable substrate can include combining an aqueous solution including a metal salt with a thermally decomposable solid substrate. In an embodiment, the aqueous solution can be nebulized and applied directly on the solid substrate. In an embodiment, the solid substrate can be macerated in the aqueous solution. The solid material, once combined with the aqueous solution, can then be calcined at a temperature ranging from about 400° C. to about 900° C. Calcination produces metal oxide nanoparticles and transforms the solid material into capping substrate molecules that are separated by the metal oxide ions. Thus, the metal oxide nanomaterials include capping substrate molecules separated by metal oxide nanoparticles. The present method reverses the conventional capping process by placing the metal oxide ions between the molecules of the capping substrate, which stay in place (keeping distance between ions), even during calcination.

A continuous process for producing a material of a battery cell using a system having a mist generator, a drying chamber, one or more gas-solid separators and a reactor is provided. A mist generated from a liquid mixture of two or more metal precursor compounds in desired ratio is dried inside the drying chamber. Heated air or gas is served as the gas source for forming various gas-solid mixtures and as the energy source for reactions inside the drying chamber and the reactor. One or more gas-solid separators are used in the system to separate gas-solid mixtures from the drying chamber into solid particles mixed with the metal precursor compounds and continuously deliver the solid particles into the reactor for further reaction to obtain final solid material particles with desired crystal structure, particle size, and morphology.