Abstract: Methods and systems for preparing electrode materials such as lithium-rich metal oxide materials, including the decomposition (e.g., via aerosol decomposition) of precursor materials, are generally provided.

Abstract: A thermal processing system includes a tilted rotary furnace configured to sinter a powder at a sintering temperature, a quenching apparatus configured to quench the sintered powder in a quench fluid, and a transfer conduit configured to provide the sintered powder having the sintering temperature from the tilted rotary furnace to the quenching apparatus in 500 ms or less.

Abstract: According to various embodiments, a method of quickly and inexpensively forming a crystallographically-stable, highly durable, cobalt-free, lithium-substituted, lithium-rich metal oxide (S-LRMO) material is provided, where the element that is used to replace lithium is some combination of Na, K, Ca, and Mg, and is above the levels commonly thought of as doping. In some embodiments, a cathode active material comprising a lithium-substituted, lithium-rich metal oxide is provided. For example, in some embodiments, the cathode active material comprises a chemical formula Li[LixAyMz]Ob, where A comprises at least one of Na, K, Ca and/or Mg. In some embodiments, (x+y) is greater than 0 and less than 0.3, y>0.05, z=1?(x+y), M includes Mn and Ni, and b is greater than or equal to 1.8 and less than or equal to 2.2.