Abstract: The present invention is directed to a method for making electrode active materials represented by the general formula: Aa(VO)bXO4, wherein: (a) A is an alkali metal or mixture of alkali metals, and 0<a<4; (b) 0<b<2; (c) X is selected from the group consisting of phosphorous (P), sulfur (S), arsenic (As), silicon (Si), and combinations thereof; and wherein A, X, a and b are selected to maintain the electroneutrality of the electrode active material in its nascent (as prepared or synthesized) state.

Abstract: A secondary electrochemical cell is described having (a) a first electrode comprising an active material of the formula LiaCoeFefM1gM2hM3iXY4, (b) a second electrode which is a counter-electrode to said first electrode; and (c) an electrolyte comprising an electrolyte salt, a cyclic ester and a carbonate selected from the group consisting of alkyl carbonates, alkylene carbonates, and mixtures thereof.

Abstract: The present invention provides for the preparation of an “optimized” VPO4 phase or V—P—O/C precursor. The VPO4 precursor is an amorphous or nanocrystalline powder. The V—P—O/C precursor is amorphous in nature and contains finely divided and dispersed carbon. Throughout the specification it is understood that the VPO4 precursor and the V—P—O/C precursor materials can be used interchangeably to produce the final vanadium phosphates, with the V—P—O/C precursor material being the preferred precursor. The precursors can subsequently be used to make vanadium based electroactive materials and use of such precursor materials offers significant advantages over other processes known for preparing vanadium phosphate compounds.

Abstract: Active materials of the invention contain at least one alkali metal and at least one other metal capable of being oxidized to a higher oxidation state. Preferred other metals are accordingly selected from the group consisting of transition metals (defined as Groups 4-11 of the periodic table), as well as certain other non-transition metals such as tin, bismuth, and lead. The active materials may be synthesized in single step reactions or in multi-step reactions. In at least one of the steps of the synthesis reaction, reducing carbon is used as a starting material. In one aspect, the reducing carbon is provided by elemental carbon, preferably in particulate form such as graphites, amorphous carbon, carbon blacks and the like. In another aspect, reducing carbon may also be provided by an organic precursor material, or by a mixture of elemental carbon and organic precursor material.

Abstract: The invention is directed to synthesizing a phosphate-based electrode active material. The method includes the step of reacting two or more starting materials collectively containing at least a PO33? anion, an alkali metal and a metal which is redox active in the final reaction product, at a temperature and for a time sufficient to form the phosphate-based electrode active material.

Abstract: Methods for producing an electrode active material precursor, comprising; a) producing a mixture comprising particles of lithium hydrogen phosphate, having a first average particle size, and a metal hydroxide, having a second average particle size; and b) grinding said mixture in a jet mill for a period of time suitable to produce a generally homogeneous mixture of particles having a third average size smaller than said first average size. The precursor may be used as a starting material for making electrode active materials for use in a battery, comprising lithium, a transition metal, and phosphate or a similar anion.

Abstract: Active materials for rechargeable batteries have a general formula Aa(MO)bM?cXO4 where A represents an alkali metal or mixture of alkali metals, a is greater than about 0.1 and less than or equal to about 2; MO is an ion containing a transition metal M not in its highest oxidation state, M? represents a metal, or mixture of metals, and b is greater than 0 and less than or equal to about 1, c is less than 1 wherein a, b and c are selected so as to maintain the electroneutrality of the compound, and X is phosphorus, arsenic, or sulfur, or mixtures thereof. Preferred active materials are alkali metal vanadyl metal phosphates of general formula Aa(VO)bM?cPO4 where a and b are both greater than 0 and c may be zero or greater. New synthetic routes are provided to alkali metal mixed metal phosphates where at least one of the starting materials is a metal-oxo group (MO)3+, where M represents a metal in a +5 oxidation state.

Abstract: The present invention is directed to a method for making electrode active materials represented by the general formula: Aa(VO)bXO4, wherein: (a) A is an alkali metal or mixture of alkali metals, and 0<a<4; (b) 0<b<2; (c) X is selected from the group consisting of phosphorous (P), sulfur (S), arsenic (As), silicon (Si), and combinations thereof; and wherein A, X, a and b are selected to maintain the electroneutrality of the electrode active material in its nascent (as prepared or synthesized) state.

Abstract: Electrode active materials comprising lithium or other alkali metals, a transition metal, and a phosphate or similar moiety, of the formula: Aa+xMbP1-xSixO4 wherein (a) A is selected from the group consisting of Li, Na, K, and mixtures thereof, and 0<a<1.0 and 0?x?1; (b) M comprises one or more metals, comprising at least one metal which is capable of undergoing oxidation to a higher valence state, where 0<b?2; and wherein M, a, b, and x are selected so as to maintain electroneutrality of said compound.

Abstract: Sodium ion batteries are based on sodium based active materials selected among compounds of the general formula AaMb(XY4)cZd, wherein A comprises sodium, M comprises one or more metals, comprising at least one metal which is capable of undergoing oxidation to a higher valence state, Z is OH or halogen, and XY4 represents phosphate or a similar group. The anode of the battery includes a carbon material that is capable of inserting sodium ions. The carbon anode cycles reversibly at a specific capacity greater than 100 mAh/g.

Abstract: The invention provides an electrochemical cell which includes a first electrode and a second electrode which is a counter electrode to said first electrode, and an electrolyte material interposed there between. The first electrode includes an alkali metal phosphorous compound doped with an element having a valence state greater than that of the alkali metal.

Abstract: Active materials of the invention contain at least one alkali metal and at least one other metal capable of being oxidized to a higher oxidation state. Preferred other metals are accordingly selected from the group consisting of transition metals (defined as Groups 4-11 of the periodic table), as well as certain other non-transition metals such as tin, bismuth, and lead. The active materials may be synthesized in single step reactions or in multi-step reactions. In at least one of the steps of the synthesis reaction, reducing carbon is used as a starting material. In one aspect, the reducing carbon is provided by elemental carbon, preferably in particulate form such as graphites, amorphous carbon, carbon blacks and the like. In another aspect, reducing carbon may also be provided by an organic precursor material, or by a mixture of elemental carbon and organic precursor material.

Abstract: The invention provides a novel polyanion-based electrode active material for use in a secondary or rechargeable electrochemical cell having a first electrode, a second electrode and an electrolyte.

Abstract: This invention relates to electrode active materials, electrodes, and batteries. In particular, this invention relates to active materials comprising lithium or other alkali metals, iron, cobalt, and other transition metals, and phosphates or similar moieties.

Abstract: Methods for producing an electrode active material precursor, comprising: a) producing a mixture comprising particles of lithium hydrogen phosphate, having a first average particle size, and a metal hydroxide, having a second average particle size; and b) grinding said mixture in a jet mill for a period of time suitable to produce a generally homogeneous mixture of particles having a third average size smaller than said first average size. The precursor may be used as a starting material for making electrode active materials for use in a battery, comprising lithium, a transition metal, and phosphate or a similar anion.

Abstract: The present invention relates to a method for preparing an electroactive metal polyanion or a mixed metal polyanion comprising forming a slurry comprising a polymeric material, a solvent, a polyanion source or alkali metal polyanion source and at least one metal ion source; heating said slurry at a temperature and for a time sufficient to remove the solvent and form an essentially dried mixture; and heating said mixture at a temperature and for a time sufficient to produce an electroactive metal polyanion or electroactive mixed metal polyanion.

Abstract: A method for carrying out solid state reactions under reducing conditions is provided. Solid state reactants include at least one inorganic metal compound and a source of reducing carbon. The reaction may be carried out in a reducing atmosphere in the presence of reducing carbon. Reducing carbon may be supplied by elemental carbon, by an organic material, or by mixtures. The organic material is one that can form decomposition products containing carbon in a form capable of acting as a reductant. The reaction proceeds without significant covalent incorporation of organic material into the reaction product. In a preferred embodiment, the solid state reactants also include an alkali metal compound. The products of the method find use in lithium ion batteries as cathode active materials. Preferred active materials include lithium-transition metal phosphates and lithium-transition metal oxides.

Abstract: Active materials of the invention contain at least one alkali metal and at least one other metal capable of being oxidized to a higher oxidation state. Preferred other metals are accordingly selected from the group consisting of transition metals (defined as Groups 4–11 of the periodic table), as well as certain other non-transition metals such as tin, bismuth, and lead. The active materials may be synthesized in single step reactions or in multi-step reactions. In at least one of the steps of the synthesis reaction, reducing carbon is used as a starting material. In one aspect, the reducing carbon is provided by elemental carbon, preferably in particulate form such as graphites, amorphous carbon, carbon blacks and the like. In another aspect, reducing carbon may also be provided by an organic precursor material, or by a mixture of elemental carbon and organic precursor material.

Abstract: The present invention relates to a method for preparing a metal phosphate which comprises milling in a carbonaceous vessel a lithium source, a phosphate source, such as LiH2PO4, and a metal oxide containing a metal ion wherein the metal ion is capable of being reduced, to produced a milled mixture and heating the milled mixture in an inert atmosphere at a temperature and for a time sufficient to form a metal phosphate wherein the metal ion of the metal oxide is reduced in oxidation state without the direct addition of a reducing agent to the starting materials.

Abstract: The invention provides a novel method for making lithium mixed metal materials in electrochemical cells. The lithium mixed metal materials comprise lithium and at least one other metal besides lithium. The invention involves the reaction of a metal compound, a phosphate compound, with a reducing agent to reduce the metal and form a metal phosphate. The invention also includes methods of making lithium metal oxides involving reaction of a lithium compound, a metal oxide with a reducing agent.