US 12,315,907 B2
Rechargeable battery and catalyst materials and the means of production thereof
Mark Sceats, New South Wales (AU); Philip Hodgson, New South Wales (AU); and Khokan Kanti Majumder, Vic (AU)
Assigned to CALIX LTD, New South Wales (AU)
Filed by CALIX LTD, New South Wales (AU)
Filed on May 22, 2023, as Appl. No. 18/200,057.
Application 18/200,057 is a division of application No. 16/476,662, granted, now 11,695,103, previously published as PCT/AU2018/050017, filed on Jan. 12, 2018.
Claims priority of application No. 2017900085 (AU), filed on Jan. 12, 2017.
Prior Publication US 2023/0299257 A1, Sep. 21, 2023
Int. Cl. H01M 4/04 (2006.01); H01M 4/133 (2010.01); H01M 4/1393 (2010.01); H01M 4/505 (2010.01); H01M 4/525 (2010.01)
CPC H01M 4/0416 (2013.01) [H01M 4/0447 (2013.01); H01M 4/0459 (2013.01); H01M 4/133 (2013.01); H01M 4/1393 (2013.01); H01M 4/505 (2013.01); H01M 4/525 (2013.01)] 12 Claims
OG exemplary drawing
 
1. A process for producing materials for use in batteries, the process comprises the steps of;
processing a precursor powder of a metal salt in an externally heated flash calciner in a gas medium at a first temperature to produce a porous particle material; wherein the first temperature is below 900° C. for a residence time of between about 10-30 seconds;
flash calcining the processed precursor powder in a second calciner reactor segment with a second process gas to complete the calcination reaction to produce a calcined product wherein an exhaust temperature of the second calciner reactor segment is 350° C. to 400° C. for a residence time of up to 40 seconds or up to 650° C. for a residence time of about 3 seconds;
flash quenching the calcined product in a quenching reactor segment to produce a metal oxide; and wherein the metal oxide is mixed with oxide powders with different particle sizes to provide a high packing density with an optimum particle-particle contact points, the mixed oxides are fused together to produce a film.