Small particle electrodes by aerosol process

A method for preparing an electrode, comprising the steps of:

• generating droplets of an emulsion of a precursor material in a carrier liquid, said precursor material capable of being converted into an active material of an electrode;
• removing at least a portion of said carrier liquid from said droplet to form precursor particles;
• and
• converting said precursor particles into particles of said active electrode material.

A method for preparing an electrode, comprising the steps of:

• generating droplets of a solution of a precursor material in a carrier liquid, said precursor material capable of being converted into an active material of an electrode;
• removing at least a portion of said carrier liquid from said droplet to form precursor particles;
• converting said precursor particles into particles of said active electrode material, wherein parameters for the conversion of the droplet into an active electrode material are controlled to obtain a predetermined particle configuration:
• depositing said active electrode material onto an electrically conductive substrate.

A method for preparing an electrode, comprising the steps of:

• generating droplets of a solution of a precursor material in a carrier liquid, said precursor material capable of being converted into an active material of an electrode;
• removing at least a portion of said carrier liquid from said droplet to form precursor particles;
• converting said precursor particles into particles of said active electrode material, wherein parameters for the conversion of the droplet into an active electrode material are controlled to obtain a predetermined particle configuration wherein the step of converting said precursor particle into said active electrode material particles comprises:
• heating the precursor particles in a moving gas stream, the heat sufficient to partially convert said precursor particles to said active electrode intermediate component;
• collecting said partially converted active electrode material intermediate component particles and
• heating the partially converted material under conditions sufficient to obtain said electrode material.

A method for preparing an electrode, comprising:

• generating droplets of a solution or emulsion of a precursor material in a carrier liquid, using a carrier liquid comprising a solvent and a diluent liquid, said precursor material capable of being converted into an active material of an electrode;
• removing at least a portion of said carrier liquid from said droplet to form precursor articles;
• and
• converting said precursor particles into particles of said active electrode material.

A method for preparing an electrode comprising:

• generating droplets of a solution or emulsion of a precursor material in a carrier liquid, said precursor material capable of being converted into an active material of an electrode;
• removing at least a portion of said carrier liquid from said droplet to form precursor articles;
• heating the precursor particles in a moving gas stream, the heat sufficient to partially convert said precursor particles to an active electrode intermediate component;
• collecting said partially converted active electrode material intermediate component particles;
• and
• heating the partially converted material under conditions sufficient to obtain said active electrode material.

A method for preparing an electrode, comprising:

• generating droplets of a solution of a precursor material in a carrier liquid, said precursor material capable of being converted into an active material of an electrode;
• removing droplets of particles not having a predetermined particle property;
• removing at least a portion of said carrier liquid from said droplet to form precursor particles;
• converting said precursor particles into particles of said active electrode material.

A method for preparing an electrode, comprising the steps of:

• generating droplets of a solution of a precursor material in a carrier liquid, said precursor material capable of being converted into an active material of an electrode and selected from the group consisting of metal acetates and metal alkoxides;
• removing at least a portion of said carrier liquid from said droplet to form precursor particles;
• and
• converting said precursor particles into particles of said active electrode material.

A method for preparing an electrode, comprising:

• generating droplets of a solution or emulsion of a first precursor material in a carrier liquid, said precursor material capable of being converted into an active material of an electrode;
• removing at least a portion of said carrier liquid from said droplet to form precursor particles, so as to form a first airborne particle stream;
• generating droplets of a solution or emulsion of a second precursor material in a carrier liquid, said precursor material capable of being converted into an active material of an electrode;
• removing at least a portion of said carrier liquid from said droplet to form precursor particles, so as to form a second airborne particle stream;
• commingling the first and second airborne particle streams;
• converting said precursor particles into particles of said active electrode material;
• and
• depositing said active electrode material onto an electrically conductive substrate.