	US 12,463,267 B2
	Direct recycling and converting cathode materials into high-performance single crystal cathode materials
Jie Xiao, Richland, WA (US); Ran Yi, Richland, WA (US); Bingbin Wu, Richland, WA (US); and Yujing Bi, Richland, WA (US)
Assigned to Battelle Memorial Institute, Richland, WA (US)
Filed by Battelle Memorial Institute, Richland, WA (US)
Filed on Oct. 26, 2022, as Appl. No. 17/974,022.
Prior Publication US 2024/0145801 A1, May 2, 2024 Prior Publication US 2024/0356096 A9, Oct. 24, 2024
Int. Cl. H01M 10/54 (2006.01); C01G 53/50 (2025.01); H01M 4/36 (2006.01); H01M 4/505 (2010.01); H01M 4/525 (2010.01); H01M 4/02 (2006.01)

CPC H01M 10/54 (2013.01) [C01G 53/50 (2013.01); H01M 4/364 (2013.01); H01M 4/505 (2013.01); H01M 4/525 (2013.01); C01P 2002/50 (2013.01); C01P 2002/72 (2013.01); C01P 2004/03 (2013.01); C01P 2006/40 (2013.01); H01M 2004/028 (2013.01)]

20 Claims

1. A solid-state method for recycling a cathode material, comprising:

(a) heating a cathode material comprising lithium nickel manganese cobalt oxide in an oxygen-containing atmosphere at a temperature T₁of 400° C. to 1000° C. for an effective period of time t₁to convert the cathode material to a solid precursor; and

(b) converting the solid precursor to a product comprising monocrystalline lithium nickel manganese cobalt oxide, wherein converting the solid precursor to the product consists of steps (i) and (ii), wherein

step (i) is mixing, without reducing particle size of the solid precursor, the solid precursor with a lithium compound at a Li: precursor molar ratio of from 0.1:1 to 1.5:1 to form a first mixture in a solid state, and

step (ii) is heating the first mixture in the solid state in an oxygen-containing atmosphere at a temperature T₂of 400° C. to 1000° C. for an effective period of time t₂to form the product, the product having a formula LiNi_xMn_yM_zCO_1-x-y-2O₂, where M represents one or more dopant metals, x≥0.33, 0.01≤y<0.33, 0≤z≤0.05, and x+y+z≤1.0.