Abstract: Apparatuses and processes for forming powder are disclosed. The apparatus includes a chamber having a head plate and an array of aerosol and burner nozzles attached to the head plate for generating aerosols and flames respectively. Powder is produced by atomizing a liquid composition to project an aerosol of droplets into the chamber and heating the aerosol with flames projected by the burner nozzles.

Abstract: Multicomponent nanoparticles materials and apparatuses and processes therefor are disclosed. In one aspect of the disclosure, separate particles generated from solution or suspension or by flame synthesis or flame spray pyrolysis, and the resultant particles are mixed in chamber prior to collection or deposition. In another aspect of the disclosure, nanoparticles are synthesized in stagnation or Bunsen flames and allowed to deposit by thermophoresis on a moving substrate. These techniques are scalable allowing mass production of multicomponent nanoparticles materials and films. The foregoing techniques can be used to prepare composites and component devices comprising one or more lithium based particles intimately mixed with carbon particles.

Abstract: Processes for depositing conductive materials on substrates are disclosed which include the steps of combusting a premixed fuel and oxidant to form a stagnation flame against a moving surface which stabilizes the stagnation flame and introducing at least one precursor to the flame to form a conducting material onto the substrate.