Process for synthesizing spinel-coated single-crystal cathode active materials

A method for manufacturing cathode active material, comprising:

• creating a polycrystalline transition metal precursor by:
• creating a first mixture including one or more transition metal precursors for one or more transition metals selected from a group consisting of nickel (Ni), manganese (Mn), iron (Fe), molybdenum (Mo), niobium (Nb), magnesium (Mg), aluminum (Al), titanium (Ti), zirconium (Zr), copper (Cu), and cobalt (Co) and one or more precursors for one of a hydroxide, a carbonate, an oxalate, and an oxide;
• and
• heating and stirring the first mixture for a predetermined period;
• providing a lithium salt composition including a first lithium salt and a second lithium salt having a eutectic melting temperature less than 200° C.;
• combining the polycrystalline transition metal precursor and the lithium salt composition to create a second mixture;
• mixing the second mixture using a mixer to generate inter-frictional force and heat the lithium salt composition above the eutectic melting temperature to form a third mixture;
• and
• sintering the third mixture to form a spinel-coated single-crystal cathode active material selected from a group consisting of lithium- and manganese-rich LMR, lithium manganese oxide (LMO), lithium nickel manganese oxide (LNMO), lithium nickel manganese cobalt (NMC), lithium nickel manganese cobalt aluminum (NMCA), lithium nickel cobalt aluminum (NCA), lithium iron phosphate (LFP), and lithium manganese iron phosphate (LMFP).