Plasma synthesis of metal and lithium fluoride nanostructures

Abstract

Provided are methods and apparatus for forming electrode active materials for electrochemical cells. These materials include a metal (e.g., iron, cobalt), lithium, and fluorine and are produced using plasma synthesis or, more specifically, non-equilibrium plasma synthesis. A metal containing material, organometallic lithium containing material, and fluorine-containing material are provided into a flow reactor, mixed, and exposed to the electrical energy generating plasma. The plasma generation enhances reaction between the provided materials and forms nanoparticles of the electrode active materials. The nanoparticles may have a mean size of 1-30 nanometers and may have a core-shell structure. The core may be formed by metal, while the shell may include lithium fluoride. A carbon shell may be disposed over the lithium fluoride shell. The nanoparticles are collected and may be used to form an electrochemical cell. Besides fluoride components, these methods may be used to form oxides, chlorides, nitrides, and sulfides.