Abstract: Methodologies, systems, and devices are provided for producing metal spheroidal powder products. Dehydrogenated and spheroidized particles are prepared using a process including introducing a metal hydride feed material into a plasma torch. The metal hydride feed material is melted within a plasma in order to dehydrogenate and spheroidize the materials, forming dehydrogenated and spheroidized particles. The dehydrogenated and spheroidized particles are then exposed to an inert gas and cooled in order to solidify the particles into dehydrogenated and spheroidized particles. The particles are cooled within a chamber having an inert gas.

Abstract: Methodologies, systems, and devices are provided for producing metal spheroidal powder products. By utilizing a microwave plasma, control over spheriodization and resulting microstructure can be tailored to meet desired demands.

Abstract: Methodologies, systems, and devices are provided for producing metal spheroidal powder products. By utilizing a microwave plasma, control over spheriodization and resulting microstructure can be tailored to meet desired demands.

Abstract: Disclosed herein are materials and processes for production of lithium oxide materials, such as lithium lanthanum zirconium oxide (LLZO), having a small particle size and high density for use in lithium-ion batteries. Some embodiments are directed to forming and then heating a multiphase material comprising lithium carbonate and La2Zr2O7 in the presence of hydrogen gas at a temperature below the melting point of the lithium carbonate, such that at least a portion of the lithium carbonate decomposes to form lithium oxide. In some embodiments, the lithium oxide is heated to a temperature sufficient to crystallize the lithium oxide to form the solid electrolyte material comprising lithium lanthanum zirconium oxide (LLZO) particles.

Abstract: Disclosed herein are systems and methods for synthesis of submicron-scale or micron-scale single crystal cathode (SCC) material, such as NMC, using a feedstock and microwave plasma processing. Microwave plasma processing of these SCC materials provides a low cost, scalable approach. In some embodiments, advanced SCC materials may be synthesized through microwave plasma processing of feedstock materials, wherein the SCC materials may comprise at least 80% nickel. In some embodiments, the microwave plasma processing may enable synthesis of SCC materials with very short calcination.

Abstract: Disclosed herein are embodiments of systems and methods for recycling used solid feedstocks containing lithium powders for use in lithium-ion batteries. The used solid feedstocks may be Lithium Nickel Manganese Cobalt Oxide (NMC) materials. In some embodiments, the used solid feedstock can undergo a microwave plasma process to produce a newly usable, lithium supplemented solid precursor with augmented chemistries and physical properties.

Abstract: Methodologies, systems, and devices are provided for producing metal spheroidal powder products. Dehydrogenated and spheroidized particles are prepared using a process including introducing a metal hydride feed material into a plasma torch. The metal hydride feed material is melted within a plasma in order to dehydrogenate and spheroidize the materials, forming dehydrogenated and spheroidized particles. The dehydrogenated and spheroidized particles are then exposed to an inert gas and cooled in order to solidify the particles into dehydrogenated and spheroidized particles. The particles are cooled within a chamber having an inert gas.

Abstract: The present disclosure relates to methodologies, systems and apparatus for generating lithium ion battery materials. Starting materials are combined to form a homogeneous precursor solution including lithium, and a droplet maker is used to generate droplets of the precursor solution having controlled size. These droplets are introduced into a microwave generated plasma, where micron or sub-micron scale lithium-containing particles are formed. These lithium-containing particles are collected and formed into a slurry to form lithium ion battery materials.

Abstract: Disclosed herein are embodiments of doped and undoped spherical or spheroidal lithium lanthanum zirconium oxide (LLZO) powder products, and methods of production using microwave plasma processing, which can be incorporated into solid state lithium ion batteries. Advantageously, embodiments of the disclosed LLZO powder display a high quality, high purity stoichiometry, small particle size, narrow size distribution, spherical morphology, and customizable crystalline structure.

Abstract: Methodologies, systems, and devices are provided for producing metal spheroidal powder products. By utilizing a microwave plasma, control over spheriodization and resulting microstructure can be tailored to meet desired demands.