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

A method of producing a solid-state electrolyte material, comprising,

• forming a liquid mixture of digitally-controlled stoichiometrically amounts of a lithium-containing salt, a lanthanum-containing salt, a zirconium-containing salt, and one or more inorganic salts containing one or more metals D1, D2, . . . , DN to be mixed with a first gas flow to form a gas-liquid mixture;
• jetting a mist of the liquid mixture into a power jetting chamber;
• drying the gas-liquid mixture for a first reaction time period of less than 20 min to undergo one or more oxidation reactions in the presence of a second gas flow of a heated gas and form a gas-solid mixture;
• delivering the gas-solid mixture out of the power jetting chamber;
• separating the gas-solid mixture into one or more solid particles of the SSE material;
• delivering the one or more solid particles into an annealing chamber;
• and
• annealing the one or more solid particles of the SSE material for a second reaction time period of more than 2 hours to undergo a dynamic crystallization process in the presence of a third gas flow and obtain crystalline products, wherein the final crystalline products of the SSE materials is a ceramic material having a measured ionic conductivity (σ) of larger than 10−4 S per centimeter at 25° C., and a chemical composition of Lia Lab Zrc D1d D2e . . . DNn Ov, wherein 6.25≤a≤7.2, 2.8≤b≤3.5, 1.2≤c≤2.2, 2.0 ≤v≤12, and wherein at least one of D1, D2, . . . , DN is a metal, N≥0, 0≤d≤0.8, 0≤e≤0.8, and 0 ≤n≤0.8.

A method of producing a solid-state electrolyte (SSE) material, comprising,

• flowing a first flow of a first gas to be mixed with a liquid mixture of digitally-controlled stoichiometrically amounts of a lithium-containing salt, one or more inorganic salts containing one or more metals D1, D2, . . . , DN;
• forming a gas-liquid mixture and jetting a mist of the liquid mixture into a power jetting chamber;
• delivering a second gas flow of a heated gas into the power jetting chamber;
• drying the gas-liquid mixture for a first reaction time period of less than 20 min to undergo one or more oxidation reactions in the presence of the second gas flow and form a gas-solid mixture;
• deliver the gas-solid mixture out of the power jetting chamber;
• separate the gas-solid mixture into one or more solid particles of the SSE material;
• deliver the one or more solid particles into an annealing chamber;
• annealing the one or more solid particles of the SSE material for a second reaction time period of more than 2 hours to undergo a dynamic crystallization process in the presence of a third gas flow and obtain crystalline products;
• and
• milling the crystalline products of the SSE material to obtain nano-sized particles, wherein the crystalline products of the SSE material are in spherical clusters under scanning electronic microscopy (SEM) analysis.