Novel Intermediate Material Between Precursor and Cathode Active Material

A process for forming an active cathode material comprising:

• forming a precursor comprising a lithium salt and a multi-carboxylic acid salt of at least one of nickel, manganese or cobalt;
• heating said precursor in a first vessel to a temperature of no more than 600° C. to form an intermediate material;
• transferring said intermediate material to a second vessel;
• and
• heating said intermediate material in said second vessel to a temperature of over 600° C. to form said active cathode material.

A process for forming an active cathode material comprising:

• forming a precursor comprising a lithium oxalate and a multi-carboxylic acid salt of at least one of nickel, manganese or cobalt;
• heating said precursor in a rotary kiln vessel to a temperature of no more than 600° C. to form an intermediate material;
• and
• heating said intermediate material to a temperature of over 600° C. to form said active cathode material.

An intermediate to an active cathode material having a formula selected from the group consisting of:

• LiNixMnyCozEwO4 Formula I
• wherein E is an optional dopant;
• and
• x+y+z+w=2 and w≤0.2 and
• LiNiaMnbXcGdO2 Formula II
• wherein G is an optional dopant;
• X is Co or Al;
• and
• wherein a+b+c+d=1 and d≤0.1;
• and
• a surface area of at least 7 m2/g.