A method for manufacturing resin particles is provided. The method includes the steps of: dissolving a resin free of poly(lactic-co-glycolic acid) (PLGA) in a good solvent of the resin to prepare a resin solution; and discharging the resin solution from at least one discharge hole having an inner diameter of less than 1,000 μm into a poor solvent of the resin to form resin particles.

A method for manufacturing resin particles is provided. The method includes the steps of: dissolving a resin free of poly(lactic-co-glycolic acid) (PLGA) in a good solvent of the resin to prepare a resin solution; and discharging the resin solution from at least one discharge hole having an inner diameter of less than 1,000 μm into a poor solvent of the resin to form resin particles.

A method for producing an electrically-conductive pellet includes reducing a size of a first material. The method also includes wetting the first material to produce a first slurry. The method also includes introducing the first slurry into a fluidizer to produce a first pellet. The method also includes reducing a size of a second material. The second material is an electrically-conductive material. The method also includes wetting the second material to produce a second slurry. The method also includes applying the second slurry to the first pellet.

A method for producing an electrically-conductive pellet includes reducing a size of a first material. The method also includes wetting the first material to produce a first slurry. The method also includes introducing the first slurry into a fluidizer to produce a first pellet. The method also includes reducing a size of a second material. The second material is an electrically-conductive material. The method also includes wetting the second material to produce a second slurry. The method also includes applying the second slurry to the first pellet.

Powderized solid-state electrolytes and electroactive materials as well as related methods of manufacturing and use are disclosed. In one embodiment, an ionically conductive powder comprises a plurality of ionically conductive particles. The ionically conductive particles may comprise an ionically conductive salt dissolved in a thermoplastic polymer, with optional components (e.g., electroactive and/or inorganic solid particles) dispersed within. Related methods of producing these ionically conductive powders are also disclosed including, but are not limited to, low-temperature milling, spray drying, and aerosol polymerization. Embodiments related to using the resultant ionically conductive powders in a spray deposition process are also described.

A porous formed article includes an organic polymer resin and an inorganic ion adsorbent and having the most frequent pore size of 0.08 to 0.70 μm measured with a mercury porosimeter. Such a porous formed article can be prepared by crushing and mixing a good solvent for the organic polymer resin and the inorganic ion adsorbent to obtain slurry; dissolving the organic polymer resin and a water-soluble polymer in the slurry; shape-forming the slurry; promoting coagulation of the shape-formed product by controlling the temperature and humidity of a spatial portion coming into contact with the shape-formed product, until the shape-formed product is coagulated in a poor solvent; and coagulating the coagulation-promoted shape-formed product in a poor solvent. A production apparatus can be used to prepare such a porous formed article.

A porous formed article includes an organic polymer resin and an inorganic ion adsorbent and having the most frequent pore size of 0.08 to 0.70 μm measured with a mercury porosimeter. Such a porous formed article can be prepared by crushing and mixing a good solvent for the organic polymer resin and the inorganic ion adsorbent to obtain slurry; dissolving the organic polymer resin and a water-soluble polymer in the slurry; shape-forming the slurry; promoting coagulation of the shape-formed product by controlling the temperature and humidity of a spatial portion coming into contact with the shape-formed product, until the shape-formed product is coagulated in a poor solvent; and coagulating the coagulation-promoted shape-formed product in a poor solvent. A production apparatus can be used to prepare such a porous formed article.

A method for producing an electrically-conductive pellet includes reducing a size of a first material. The method also includes wetting the first material to produce a first slurry. The method also includes introducing the first slurry into a fluidizer to produce a first pellet. The method also includes reducing a size of a second material. The second material is an electrically-conductive material. The method also includes wetting the second material to produce a second slurry. The method also includes applying the second slurry to the first pellet.

A method for producing an electrically-conductive pellet includes reducing a size of a first material. The method also includes wetting the first material to produce a first slurry. The method also includes introducing the first slurry into a fluidizer to produce a first pellet. The method also includes reducing a size of a second material. The second material is an electrically-conductive material. The method also includes wetting the second material to produce a second slurry. The method also includes applying the second slurry to the first pellet.

Some variations provide a device for assembling a plurality of particles into particle assemblies, comprising: (a) a microfluidic droplet-generating region; (b) a first inlet to the droplet-generating region, configured to feed a first fluid containing particles and a solvent for the particles; (c) a second inlet to the droplet-generating region, configured to feed a second fluid that is not fully miscible with the first fluid; (d) a droplet outlet from the droplet-generating region, configured to withdraw droplets of the first fluid dispersed in the second fluid; and (e) a droplet-dissolving region configured to remove solvent from the droplets, thereby forming particle assemblies. Some variations also provide an assembly of nanoparticles, wherein the assembly has a volume from 1 μm.sup.3 to 1 mm.sup.3, a packing fraction from 20% to 100%, and/or an average relative surface roughness less than 1%, wherein the assembly is not disposed on a substrate.