Abstract: A curing process for cathode material alleviates surface defects on particles of the cathode material for improving battery performance. Heat treating a granular form of the cathode material in a flow of an oxygen-containing gas removes surface defects on the cathode material particles that have been mechanically deagglomerated. This results in significant improvement in both the rate of charge/discharge and the number of recharge cycles.

Abstract: A Li-ion cathode material is prepared by a multi-stage lithiation process that separates a total amount of lithium called for by the recycled battery to be used in a series of sintering stages. A leaching, ratio adjustment and coprecipitation sequence forms a cathode precursor having a predetermined ratio of metallic elements from a comingled recycling stream of Li-ion batteries. The precursor is sintered with a lithium salt in a sequence of stages, each having a portion of the total lithium quantity, for a predetermined duration and temperature. The initial sintering stage tends to define the crystallinity of the resulting active cathode material and has a particle size determined at least in part by the portion of lithium at each stage.

Abstract: Various lithium cobalt oxides materials having a chemical formula of Lix Coy Oz, and method and apparatus of producing the various lithium cobalt oxides materials are provided. The method includes adjusting a molar ratio MLiSalt:MCoSalt of a lithium-containing salt, and a cobalt-containing salt within a liquid mixture to be equivalent to a ratio of x:y, drying a mist of the liquid mixture in the presence of a gas to form a gas-solid mixture, separating the gas-solid mixture into one or more solid particles of an oxide material, and annealing the solid particles of the oxide material in the presence of another gas flow to obtain crystalized particles of the lithium cobalt oxide material. The process system has a mist generator, a drying chamber, one or more gas-solid separator, and one or more reactors.

Abstract: Various lithium cobalt oxides materials having a chemical formula of Lix Coy Oz, and method and apparatus of producing the various lithium cobalt oxides materials are provided. The method includes adjusting a molar ratio MLiSalt:MCoSalt of a lithium-containing salt, and a cobalt-containing salt within a liquid mixture to be equivalent to a ratio of x:y, drying a mist of the liquid mixture in the presence of a gas to form a gas-solid mixture, separating the gas-solid mixture into one or more solid particles of an oxide material, and annealing the solid particles of the oxide material in the presence of another gas flow to obtain crystalized particles of the lithium cobalt oxide material. The process system has a mist generator, a drying chamber, one or more gas-solid separator, and one or more reactors.

Abstract: A battery recycling process aggregates a recycling stream including charge material metals from exhausted Li-ion batteries and generates recycled battery charge material having comparable or improved cycle life as well as recycled charge material precursor having fewer cracking defects using doping substances in a coprecipitation phase in the recycling sequence. In a coprecipitation process, a solution of comingled charge material metals is produced, the ratio of the charge material metals is adjusted based on recycled battery specifications, and a relatively small quantity of a doping salt is added.

Abstract: A battery recycling process aggregates a recycling stream including charge material metals from exhausted Li-ion batteries and generates recycled battery charge material having comparable or improved cycle life as well as recycled charge material precursor having fewer cracking defects using doping substances in a coprecipitation phase in the recycling sequence. In a coprecipitation process, a solution of comingled charge material metals is produced, the ratio of the charge material metals is adjusted based on recycled battery specifications, and a relatively small quantity of a doping salt is added.

Abstract: A recycling process for Lithium-ion (Li-ion) batteries includes a selective leach of charge material metals followed by impurity control for effecting microstructures such as a pore volume and surface area for optimal structures and charge performance. Particle characteristics having a favorable effect on performance correlate with soluble impurities in a recycling leach solution formed from spent charge material in a battery recycling stream. Spent batteries yield a black mass of agitated, comingled cathode material, anode material and current collectors. Leaching of the black mass yields a recycling solution of charge material metals and impurities. Selective adjustment of these impurities through adding and/or separating soluble ions in the solution drives formation of internal voids, surface area and pore volume in the resulting cathode material.

Abstract: Various lithium cobalt oxides materials having a chemical formula of LixCoyOz, and method and apparatus of producing the various lithium cobalt oxides materials are provided. The method includes adjusting a molar ratio MLiSalt:MCoSalt of a lithium-containing salt, and a cobalt-containing salt within a liquid mixture to be equivalent to a ratio of x:y, drying a mist of the liquid mixture in the presence of a gas to form a gas-solid mixture, separating the gas-solid mixture into one or more solid particles of an oxide material, and annealing the solid particles of the oxide material in the presence of another gas flow to obtain crystallized particles of the lithium cobalt oxide material. The process system has a mist generator, a drying chamber, one or more gas-solid separator, and one or more reactors.

Abstract: Silicon oxide based materials, including composites with various electrical conductive compositions, are formulated into desirable anodes. The anodes can be effectively combined into lithium ion batteries with high capacity cathode materials. In some formulations, supplemental lithium can be used to stabilize cycling as well as to reduce effects of first cycle irreversible capacity loss. Batteries are described with surprisingly good cycling properties with good specific capacities with respect to both cathode active weights and anode active weights.

Abstract: Various lithium cobalt oxides materials doped with one or more metal dopants having a chemical formula of LixCoyOz (doped Me1a Me2b Me3c . . . MeNn), and method and apparatus of producing the various lithium cobalt oxides materials are provided. The method includes adjusting a molar ratio MLiSalt:MCoSalt:MMe1Salt:MMe2Salt:MMe3Salt:. . . MMeNSalt of a lithium-containing salt, a cobalt-containing salt and one or more metal-dopant-containing salts within a liquid mixture to be equivalent to a ratio of x:y:a:b:c: . . . n , drying a mist of the liquid mixture in the presence of a gas to form a gas-solid mixture, separating the gas-solid mixture into one or more solid particles of an oxide material, and annealing the solid particles of the oxide material in the presence of another gas flow to obtain crystalized particles of the lithium cobalt oxide material. The process system has a mist generator, a drying chamber, one or more gas-solid separator, and one or more reactors.

Abstract: Various lithium cobalt oxides materials having a chemical formula of LixCoyOz, and method and apparatus of producing the various lithium cobalt oxides materials are provided. The method includes adjusting a molar ratio MLiSalt:MCoSalt of a lithium-containing salt, and a cobalt-containing salt within a liquid mixture to be equivalent to a ratio of x:y, drying a mist of the liquid mixture in the presence of a gas to form a gas-solid mixture, separating the gas-solid mixture into one or more solid particles of an oxide material, and annealing the solid particles of the oxide material in the presence of another gas flow to obtain crystallized particles of the lithium cobalt oxide material. The process system has a mist generator, a drying chamber, one or more gas-solid separator, and one or more reactors.

Abstract: Composite silicon based materials are described that are effective active materials for lithium ion batteries. The composite materials comprise processed, e.g., high energy mechanically milled, silicon suboxide and graphitic carbon in which at least a portion of the graphitic carbon is exfoliated into graphene sheets. The composite materials have a relatively large surface area, a high specific capacity against lithium, and good cycling with lithium metal oxide cathode materials. The composite materials can be effectively formed with a two-step high energy mechanical milling process. In the first milling process, silicon suboxide can be milled to form processed silicon suboxide, which may or may not exhibit crystalline silicon x-ray diffraction. In the second milling step, the processed silicon suboxide is milled with graphitic carbon. Composite materials with a high specific capacity and good cycling can be obtained in particular with balancing of the processing conditions.

Abstract: Improved high energy capacity designs for lithium ion batteries are described that take advantage of the properties of high specific capacity anode active compositions and high specific capacity cathode active compositions. In particular, specific electrode designs provide for achieving very high energy densities. Furthermore, the complex behavior of the active materials is used advantageously in a radical electrode balancing design that significantly reduced wasted electrode capacity in either electrode when cycling under realistic conditions of moderate to high discharge rates and/or over a reduced depth of discharge.

Abstract: Silicon oxide based materials, including composites with various electrical conductive compositions, are formulated into desirable anodes. The anodes can be effectively combined into lithium ion batteries with high capacity cathode materials. In some formulations, supplemental lithium can be used to stabilize cycling as well as to reduce effects of first cycle irreversible capacity loss. Batteries are described with surprisingly good cycling properties with good specific capacities with respect to both cathode active weights and anode active weights.

Abstract: Improved high energy capacity designs for lithium ion batteries are described that take advantage of the properties of high specific capacity anode active compositions and high specific capacity cathode active compositions. In particular, specific electrode designs provide for achieving very high energy densities. Furthermore, the complex behavior of the active materials is used advantageously in a radical electrode balancing design that significantly reduced wasted electrode capacity in either electrode when cycling under realistic conditions of moderate to high discharge rates and/or over a reduced depth of discharge.

Abstract: High capacity silicon based anode active materials are described for lithium ion batteries. These materials are shown to be effective in combination with high capacity lithium rich cathode active materials. Supplemental lithium is shown to improve the cycling performance and reduce irreversible capacity loss for at least certain silicon based active materials. In particular silicon based active materials can be formed in composites with electrically conductive coatings, such as pyrolytic carbon coatings or metal coatings, and composites can also be formed with other electrically conductive carbon components, such as carbon nanofibers and carbon nanoparticles. Additional alloys with silicon are explored.

Abstract: Various lithium cobalt oxides materials doped with one or more metal dopants having a chemical formula of Lix Coy Oz (doped Me1a Me2b Me3c . . . MeNn), and method and apparatus of producing the various lithium cobalt oxides materials are provided. The method includes adjusting a molar ratio MLiSalt:MCoSalt:MMe1Salt:MMe2Salt:MMe3Salt: . . . MMeNSalt of a lithium-containing salt, a cobalt-containing salt and one or more metal-dopant-containing salts within a liquid mixture to be equivalent to a ratio of x:y:a:b:c: . . . n, drying a mist of the liquid mixture in the presence of a gas to form a gas-solid mixture, separating the gas-solid mixture into one or more solid particles of an oxide material, and annealing the solid particles of the oxide material in the presence of another gas flow to obtain crystalized particles of the lithium cobalt oxide material. The process system has a mist generator, a drying chamber, one or more gas-solid separator, and one or more reactors.

Abstract: Various lithium cobalt oxides materials having a chemical formula of Lix Coy Oz, and method and apparatus of producing the various lithium cobalt oxides materials are provided. The method includes adjusting a molar ratio MLiSalt:MCoSalt of a lithium-containing salt, and a cobalt-containing salt within a liquid mixture to be equivalent to a ratio of x:y, drying a mist of the liquid mixture in the presence of a gas to form a gas-solid mixture, separating the gas-solid mixture into one or more solid particles of an oxide material, and annealing the solid particles of the oxide material in the presence of another gas flow to obtain crystalized particles of the lithium cobalt oxide material. The process system has a mist generator, a drying chamber, one or more gas-solid separator, and one or more reactors.

Abstract: High capacity silicon based anode active materials are described for lithium ion batteries. These materials are shown to be effective in combination with high capacity lithium rich cathode active materials. Supplemental lithium is shown to improve the cycling performance and reduce irreversible capacity loss for at least certain silicon based active materials. In particular silicon based active materials can be formed in composites with electrically conductive coatings, such as pyrolytic carbon coatings or metal coatings, and composites can also be formed with other electrically conductive carbon components, such as carbon nanofibers and carbon nanoparticles. Additional alloys with silicon are explored.

Abstract: Composite silicon based materials are described that are effective active materials for lithium ion batteries. The composite materials comprise processed, e.g., high energy mechanically milled, silicon suboxide and graphitic carbon in which at least a portion of the graphitic carbon is exfoliated into graphene sheets. The composite materials have a relatively large surface area, a high specific capacity against lithium, and good cycling with lithium metal oxide cathode materials. The composite materials can be effectively formed with a two-step high energy mechanical milling process. In the first milling process, silicon suboxide can be milled to form processed silicon suboxide, which may or may not exhibit crystalline silicon x-ray diffraction. In the second milling step, the processed silicon suboxide is milled with graphitic carbon. Composite materials with a high specific capacity and good cycling can be obtained in particular with balancing of the processing conditions.