Large-scale synthesis of powders of solid-state electrolyte material particles for solid-state batteries, systems and methods thereof

Abstract

Various solid-state electrolyte materials having a desired chemical composition as well as method and apparatus of producing the solid-state electrolyte (SSE) materials are provided. The method includes drying a gas-liquid mixture to form a gas-solid mixture, obtaining powdered particles, and annealing the powdered particles to obtain crystalline products of the SSE material. The liquid mixture is prepared using stoichiometrically amounts of lithium-containing salt and one or more inorganic salts and then mixed with a gas. The salts are prepared in solutions and the molar ratio of the solutions of lithium-containing salt and the one or more inorganic metal salt are digitally controlled, thereby obtaining large scale synthesis of the SSE materials. The processing apparatus generally includes a mist generator, a power jetting chamber, one or more gas-solid separators, and one or more reactors. Various types of SSE materials can then be prepared and obtained.