Patent ID: 7060206

Claim:
A process for producing an active material having general formula A a M b (XY 4 ) c Z d , wherein (a) A is selected from the group consisting of Li, Na, K, and mixtures thereof, and 0<a≦8; (b) M comprises one or more metals, comprising at least one metal which is capable of undergoing oxidation to a higher valence state, and 1≦b≦3; (c) XY 4 is selected from the group consisting of X′O 4−x Y′ x , X′O 4−y Y′ 2y , X″S 4 , and mixtures thereof, where X′ is selected from the group consisting of P, As, Sb, Si, Ge, V, S, and mixtures thereof; X″ is selected from the group consisting of P, As, Sb, Si, V, Ge and mixtures thereof; Y′ is selected from the group consisting of halogen, S,or N; 0≦x<3; and 0<y≦2; and 0<c≦3; and (d) Z is OH, halogen, or mixtures thereof, and 0≦d≦6; comprising the steps of: combining first starting materials to form a first mixture, the first starting materials comprising at least one metal and at least one source of carbohydrate present in an amount sufficient to reduce the oxidation state of at least one metal ion of the metal without full reduction to elemental state; heating the first mixture at a temperature and for a time sufficient to form a reaction product, wherein at least one metal of the starting materials is reduced in oxidation state during heating to form an inorganic metal compound; combining second starting materials to form a second mixture, the second starting materials comprising at least one alkali metal compound and the inorganic metal compound formed in the previous step; and in a subsequent step, heating the second mixture at a temperature and for a time sufficient to form a reaction product comprising the active material; wherein the first and second starting materials together comprise at least one source of alkali metal A, at least one source of metal M, at least one source of XY 4 , and, if d>0, at least one source of halide or hydroxide Z.