Abstract: A process for preparing a coated cathode active material for use in energy storage devices that includes the steps of providing at least one coating material having an average D50 particle size that is in the range of 0.01-1.5 ?m; providing one or more cathode active materials; blending the at least one coating material and the one or more cathode active materials with a plurality of milling beads to form a dry mixture, wherein the milling beads have a bead size ranging from 0.1 mm to 2.0 mm; rotating the dry mixture at a speed that is in the range of 50 rpm to 800 rpm for one or more hours to form the coated cathode active material; and separating the coated cathode active material from the milling beads. The coated cathode active material has an average particle size in the range of 2 ?m to 30 ?m.

Abstract: A method of stabilizing Nickel-rich (NMC) cathode materials includes mixing a feedstock of transition metal sulfates, ammonia, and a basic solution to under bubbling of an inert gas to form a reaction solution, precipitating transition metal hydroxide particles from the reaction solution over a first period of time to precipitate the transition metal hydroxide particles therein to form a metal sulfate solution. The method further includes altering the pH of the metal sulfate solution, supplying a Mn-rich feedstock to the metal sulfate solution to form a Mn-rich solution, and precipitating Mn-rich hydroxide nanoparticles from the Mn-rich solution onto surfaces of the transition metal hydroxide particles over a second period of time to form a heterogeneous precursor.