Electrode active composite materials and methods of making thereof

1. A method of synthesizing a lithium metal phosphate composite usable for a lithium secondary battery, comprising the steps of:

forming a nanometer-size precursor from a mixture of a first solution having metal ions and a second solution having phosphate ions and a carbon source, wherein the metal of the metal ions is a transitional metal or a combination of transitional metals, and the nanometer-size precursor comprises metal phosphate nanoparticles, each metal phosphate nanoparticle being at least partially covered by a layer of carbon precursor, and wherein the layer of carbon precursor is coated through in situ oxidation polymerization during the formation of the nanometer-size metal phosphate nanoparticles;

adding a stoichiometric ratio of a lithium source to the nanometer-size precursor and mixing therewith to form a precursor mixture comprising lithium metal phosphate nanoparticles;

spray drying the precursor mixture at a temperature ranged from about 20° C. to about 500° C. to form micron-size particles, wherein the micron-size particles are packed with the lithium metal phosphate nanoparticles; and

sintering the micron-size particles at a temperature ranged from about 500° C. to about 1200° C. under an inert and/or reduction atmosphere to form a micron-size spherical lithium metal phosphate composite, wherein the micron-size spherical lithium metal phosphate composite comprises the lithium metal phosphate nanoparticles, each lithium metal phosphate nanoparticle being coated at least partially with a layer of carbon.

2. The method of claim 1 , wherein the inert and/or reduction atmosphere comprises an argon and hydrogen gas mixture.

3. The method of claim 1 , wherein the metal is Fe, Mn, V, Co, Ni, or a combination of them.

4. The method of claim 1 , wherein the layer of carbon-precursor is coated on at least a portion of each metal phosphate nanoparticle.

5. The method of claim 4 , wherein the layer of carbon-precursor has a thickness in a range of about 0.5-100 nm.

6. The method of claim 4 , wherein the layer of carbon-precursor comprises at least one of carbonaceous materials.

7. The method of claim 1 , wherein the lithium metal phosphate nanoparticles self-organize to form the micron-size lithium metal phosphate composite.

8. The method of claim 1 , wherein the micron-size lithium metal phosphate composite has a tap density that is in a range of about 0.5 to 3 g/cm 3 .

9. The method of claim 1 , wherein the percentage of carbon in the lithium metal phosphate composite is less than about 28.8%.

10. The method of claim 1 , wherein the nanometer-size precursor has a size in a range of about 1-500 nm.

11. The method of claim 1 , wherein the micron-size lithium metal phosphate composite has a size in a range of about 1-100 μm.

12. The method of claim 1 , wherein the micron-size lithium metal phosphate composite has a particle size distribution characterized with a median size that is in a range of about 1-100 μm, and a standard deviation that is no more than 50% of the median size.

13. The method of claim 1 , wherein the lithium metal phosphate nanoparticle has a size less than about 1.0 μm.

14. The method of claim 13 , wherein the lithium metal phosphate nanoparticles have a size distribution characterized with a median size that is less than 1.0 μm, and a standard deviation that is no more than 50% of the median size.