Methods and systems for producing lithium intercalated anodes

Abstract

Embodiments of the present disclosure generally relate to battery technology, and more particularly, methods and systems for preparing lithium anodes. In one or more embodiments, a method for producing a lithium intercalated anode includes introducing a sacrificial substrate comprising a lithium film and an anode substrate comprising graphite into a processing region within a chamber. The method further includes bonding the sacrificial substrate and the anode substrate to overlap each other around a rewinding roller, rotating the rewinding roller to wind the sacrificial substrate and the anode substrate together to produce a wound anode-sacrificial substrate bundle during the winding process. The method further includes heating the sacrificial substrate, the anode substrate, and / or the wound anode-sacrificial substrate bundle while rotating the rewinding roller and applying a force to the wound anode-sacrificial substrate bundle via the idle roller during the winding process.

Description

Technical Field

[0001] Embodiments of the present disclosure relate generally to battery technology, and more particularly, to methods and systems for preparing lithium anodes. Background Art

[0002] Battery technology, including rechargeable electrochemical storage systems, is becoming increasingly valuable for many areas of daily life. High-capacity electrochemical energy storage devices such as lithium-ion (Li-ion) batteries are increasingly used in a wide range of applications, including electric vehicles (EVs), portable electronics, medical, transportation, grid-connected large-scale energy storage, renewable energy storage, and uninterruptible power supplies (UPS). Conventional lead / sulfuric acid batteries are generally insufficient in capacity, too heavy, and often not cycle-capable enough for these growing applications. However, lithium-ion batteries are considered to have the best opportunities.

[0003] Typically, for safety reasons, lithium-ion batteries do not contain solid metallic lithium anodes, but instead use lithium-containing graphite materials as anodes. However, using graphite (which can be charged to the limit component LiC in a charged state) is not a good idea. 6 ) has a much lower capacity than using metallic lithium anodes. Currently, the industry is moving from graphite-based anodes to silicon-hybrid graphite to increase battery density. However, silicon-hybrid graphite anodes suffer from first cycle capacity loss. Therefore, lithium metal deposition is required to replenish the first cycle capacity loss of silicon-hybrid graphite anodes. However, lithium metal faces several device integration challenges.

[0004] Lithium is a first-group element similar to the other alkali metals. Lithium is characterized by its strong reactivity with a wide range of substances. Lithium reacts violently with water, alcohols, and other substances containing protonated hydrogen, often resulting in fire. Lithium is unstable in air and reacts with oxygen, nitrogen, and carbon dioxide. Lithium is usually handled under an inert gas atmosphere (rare gases such as argon), and the strong reactivity of lithium necessitates that other processing operations must also be performed in an inert gas atmosphere. Therefore, lithium poses several challenges when handling, storing, and / or transporting lithium.

[0005] Therefore, there is a need for improved methods and systems for producing lithium intercalation anodes. Summary of the invention

[0006] Embodiments of the present disclosure relate generally to battery technology, and more specifically, to methods and systems for preparing alkaline anodes (e.g., lithium anodes). In one or more embodiments, a method for forming or otherwise producing a lithium intercalation anode is provided, comprising introducing a sacrificial substrate into a processing region within a chamber and introducing an anode substrate into a processing region within a chamber. The sacrificial substrate may be or include a base foil having an upper surface opposite to a lower surface and a lithium coating disposed on the upper surface and the lower surface. The anode substrate may include graphite or a graphite material. The method also includes combining the sacrificial substrate and the anode substrate overlapping each other around a rewinder roller within the processing region during a winding or wrapping process. The method further includes rotating the rewinding roller to wind the sacrificial substrate and the anode substrate together to produce a wound anode-sacrificial substrate bundle, while continuing to introduce the sacrificial substrate and the anode substrate into the processing region during the winding or wrapping process. The method further includes heating the sacrificial substrate, the anode substrate and / or the wound anode-sacrificial substrate bundle while rotating the rewind roller and applying a force to the wound anode-sacrificial substrate bundle via an idle roller during the winding or wrapping process.

[0007] In other embodiments, a method of forming or otherwise producing a lithium intercalation anode is provided and includes introducing a sacrificial substrate into a processing region within a chamber, wherein the sacrificial substrate may be or include a base foil having an upper surface opposite to a lower surface and a lithium coating disposed on the upper surface and the lower surface, and introducing the anode substrate into the processing region within the chamber. The method also includes rotating a rewinding roller within the processing region to wind the sacrificial substrate and the anode substrate together and overlap each other to produce a wound anode-sacrificial substrate bundle, while continuing to introduce the sacrificial substrate and the anode substrate into the processing region during the winding process. The processing region is maintained at a vacuum of less than 760 Torr, for example, at a pressure of about 1×10 -6 mTorr to about 1×10 -3 mTorr range, while producing a wound anode-sacrificial substrate bundle. The method further includes heating the sacrificial substrate, the anode substrate and / or the wound anode-sacrificial substrate bundle, while rotating the rewinding roller during the winding process, and applying a force to the wound anode-sacrificial substrate bundle via an idle roller during the winding process. The method further includes transferring at least a portion of the lithium metal from the sacrificial substrate to the anode substrate and absorbing the lithium metal into the anode substrate to produce a lithium intercalated anode substrate.

[0008] In some embodiments, a system for forming or otherwise producing a lithium intercalation anode is provided, the system comprising a chamber having a processing region therein and configured to maintain the processing region under vacuum, such as at a pressure less than ambient pressure (e.g., <760 Torr). The system also includes a first source coupled to the chamber and comprising a sacrificial substrate, the sacrificial substrate comprising a base foil having an upper surface opposite a lower surface and a lithium coating disposed on the upper surface and the lower surface, and a second source comprising an anode substrate coupled to the chamber and comprising graphite. The system further includes a rewinding roller disposed within the processing region and configured to receive the sacrificial substrate and the anode substrate and wind the sacrificial substrate and the anode substrate together to produce a wound anode-sacrificial substrate bundle, and also includes a calendaring system comprising an idle roller, which is configured to apply a force to the wound anode-sacrificial substrate bundle, and one or more infrared lamps contained within the processing region and positioned on the sacrificial substrate, the anode substrate, and / or the wound anode-sacrificial substrate bundle. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] In order to be able to understand in detail the manner in which the above-mentioned features of the present disclosure are achieved, a more specific description of the present disclosure briefly summarized above can be obtained by reference to embodiments, some of which are shown in the accompanying drawings. However, it should be noted that the drawings only show exemplary embodiments and therefore should not be considered as limiting the scope thereof, and other equally effective embodiments may be allowed.

[0010] Figure 1 Depicted is a schematic diagram of a processing system for forming a wound anode-sacrificial substrate bundle as an intermediate for a lithium intercalation anode according to one or more embodiments described and discussed herein.

[0011] Figure 2A Depicted is a schematic diagram of a wound anode-sacrificial substrate bundle according to one or more embodiments described and discussed herein.

[0012] Figure 2B Depicted is a schematic diagram of a sacrificial substrate according to one or more embodiments described and discussed herein.

[0013] Figure 3 Depicted is a perspective view of a calendaring system that may be used in a processing system for forming a wound anode-sacrificial substrate bundle according to one or more embodiments described and discussed herein.

[0014] Figures 4A-4E Depicts multiple views of a calendaring system according to one or more embodiments described and discussed herein, such as Figure 3 As shown, the calendaring system is included in a processing system for forming a wound anode-sacrificial substrate bundle.

[0015] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation. DETAILED DESCRIPTION

[0016] Embodiments of the present disclosure relate generally to battery technology, and more specifically, to methods and systems for preparing alkaline anodes, such as lithium intercalation anodes. The method includes transferring lithium from a sacrificial substrate to an anode substrate by a heated lamination technique. Typically, lithium is transferred from a sacrificial substrate to an anode substrate in a roll-to-roll (R2R) vacuum chamber or other processing chamber. In one or more instances, lithium is an alkali metal that is transferred to the anode substrate to produce a lithium intercalation anode. However, in some instances, the method can be used to transfer other alkali metals (e.g., sodium, potassium, or cesium) to the anode substrate.

[0017] In one or more embodiments, a method for producing or otherwise forming a lithium intercalation anode includes introducing a sacrificial substrate and an anode substrate into a processing region under vacuum in a chamber. The sacrificial substrate may include a base foil having an upper surface opposite to a lower surface and a lithium coating disposed on the upper surface and the lower surface. The anode substrate may be or include graphite or one or more graphite-containing materials. The method also includes winding the sacrificial substrate and the anode substrate together to produce a wound anode-sacrificial substrate bundle, while heating the sacrificial substrate, the anode substrate and / or the wound anode-sacrificial substrate bundle, and applying force to the wound anode-sacrificial substrate bundle during the winding or winding process. Within a predetermined period of time, the wound anode-sacrificial substrate bundle is maintained under vacuum while at least a portion of the lithium metal is transferred from the sacrificial substrate to the anode substrate and absorbed into the anode substrate to produce a lithium intercalation anode substrate. The base foil and any remaining lithium metal thereon may be separated from the lithium intercalation anode substrate.

[0018] Figure 1 A schematic diagram of a processing system for forming a wound anode-sacrificial substrate bundle as an intermediate for a lithium intercalation anode is depicted according to one or more embodiments described and discussed herein. In one or more embodiments, a processing system 100 for forming or otherwise producing a lithium intercalation anode is provided, which includes a chamber 102 (e.g., a rewinding chamber) having one or more processing regions 104 therein. The chamber 102 is configured to maintain the processing region 104 under vacuum, such as at a pressure less than ambient pressure (e.g., <760 Torr). One or more vacuum pumps 106 are coupled to the chamber 102 and in fluid communication therewith, and are configured to control the pressure of the processing region 104. In one or more embodiments, the processing system 100 includes a processing chamber (not shown) coupled to and between an unwinder chamber (not shown) and the chamber 102 (e.g., a rewinding chamber).

[0019] The processing system 100 also includes two or more sources 112, 122 of various substrates used during the processing techniques described and discussed herein. The processing system 100 includes a first source 112 of a sacrificial substrate 110 coupled to the chamber 102. The first source 112 contains and / or provides the sacrificial substrate 110. In some examples, the first source 112 can be external to the chamber 102 and provide the sacrificial substrate 110 into the processing region 104. The processing system 100 also includes a second source 122 of an anode substrate 120 coupled to the chamber 102. The second source 122 contains and / or provides the anode substrate 120. In some examples, the second source 122 can be external to the chamber 102 and provide the anode substrate 120 into the processing region 104.

[0020] Figure 2A depicts a schematic diagram of a wound anode-sacrificial substrate bundle 200 once removed from a rewind roll 130 in accordance with one or more embodiments described and discussed herein, and Figure 2B Schematic diagram of a sacrificial substrate 110 is depicted. In one or more embodiments, the sacrificial substrate 110 includes a base foil 108 having an upper surface 108a opposite to a lower surface 108b and a lithium coating 111 disposed on the upper surface 108a and the lower surface 108b, such as Figure 2A-2B As shown in . The lithium coating 111 may be or include metallic lithium or a lithium alloy. In other embodiments, the lithium coating 111 may be replaced by another metal film disposed on the upper surface 108a and the lower surface 108b. For example, one or more metals (including one or more alkali metals) may be disposed on the upper and lower surfaces 108a, 108b and used to form a wound anode-sacrificial substrate bundle 200 and subsequently produce a corresponding metal anode substrate. Exemplary metals may be or include lithium, sodium, potassium, cesium, alloys thereof, or any combination thereof.

[0021] In one or more embodiments, the base foil 108 of the sacrificial substrate 110 may be or include one or more metals and / or one or more polymer materials. For example, the base foil 108 may be or include one or more metals (e.g., copper), one or more copper alloys, nickel, one or more nickel alloys, one or more stainless steel alloys (their alloys), or any combination thereof. In other examples, the base foil 108 may be or include one or more polymer materials, such as polyethylene terephthalate (PET), polypropylene (PP), their copolymers, their elastomers, or any combination thereof. In one or more examples, the base foil 108 may be or include copper foil or sheet and / or PET foil or sheet. In one or more embodiments, the anode substrate 120 may be or include graphite, graphite foil, graphite sheet, silicon-graphite material, silicon oxide-graphite material, or any combination thereof. In one or more examples, the anode substrate 120 may be or include graphite foil and / or silicon-graphite foil.

[0022] The processing system 100 and / or the chamber 102 further includes a rewind roller 130 disposed within the processing region 104. The rewind roller 130 is configured to receive the sacrificial substrate 110 and the anode substrate 120 and wind them together to produce or otherwise form a coiled anode-sacrificial substrate bundle 200 that is wound around the rewind roller 130. In one or more examples, the chamber 102 is a rewind chamber, and the processing region 104 and the rewind roller 130 are both contained within the rewind chamber.

[0023] The processing system 100 may include one or more rollers 114 to help deliver, transport and / or support the sacrificial substrate 110 and one or more rollers 124 to help deliver, transport and / or support the anode substrate 120. Figure 1 , roller 114 may be located between first source 112 and rewind roller 130 and configured to assist in supporting and delivering sacrificial substrate 110 to rewind roller 130. Similarly, roller 124 may be located between second source 122 and rewind roller 130 and configured to assist in supporting and delivering anode substrate 120 to rewind roller 130.

[0024] like Figure 1 As shown, the processing system 100 includes a calendaring system 300 that includes deadweight or idle rollers 320 configured to apply force to the wound anode-sacrificial substrate bundle 200 during the process of winding the sacrificial substrate 110 and the anode substrate 120 together. Figure 3 A perspective view of a calendaring system 300 is depicted, which may be used in various processing systems, such as the processing system 100 for forming a wound anode-sacrificial substrate bundle 200, in accordance with one or more embodiments described and discussed herein. Figures 4A-4EVarious views of a calendaring system 300 included within the processing system 100 are depicted.

[0025] The calendaring system 300 includes a support beam 310, two pivot arms 314 coupled to the support beam 310, and an idle roller 320 coupled to the pivot arms 314 and located between the pivot arms 314. One, two or more brackets 312 may be used to support, couple or attach the support beam 310 to the interior surface 103 within the processing system 100. Figures 4A-4C As shown, each end of the support beam 310 is secured by a corresponding bracket 312, which in turn is attached to the inner surface 103 of the processing system 100 by a plurality of fasteners (e.g., bolts, screws, rivets). The calendaring system 300 also includes a bar 332 coupled to and located between the pivot arms 314, such as attached to the upper surface of each pivot arm 314. A handle 334 is coupled to the bar 332 and is configured to adjust the angle of the pivot arm 314 relative to the support beam 310. A plurality of adjustment bolts 318 are disposed on or near the end of each pivot arm 314 closest to the support beam 310. The adjustment bolts 318 are loosened, and then the pivot arm 314 is manually adjusted to a desired angle via the handle 334, and then the adjustment bolts 318 are tightened to fix the desired angle of the pivot arm 314.

[0026] The inner surface on each pivot arm 314 includes a track or slide slot 316 that extends a majority of the length of the pivot arm and is configured to support an idle roller 320. The calendaring system 300 also includes two casters 322 coupled to the idle rollers. Each caster 322 is coupled to opposite ends of the idle roller 320 and is configured to assist in moving the idle roller 320. Each caster 322 is configured to travel within a corresponding track or slide slot 316 on each pivot arm 314.

[0027] In one or more examples, the idle roller 320 is positioned within the processing system 100 and is configured to move radially away from the rewind roller 130 as the diameter of the wound anode-sacrificial substrate bundle 200 increases during production of the sacrificial substrate 110 and the anode substrate 120. Additionally, the idle roller 320 maintains a controlled force applied to the wound anode-sacrificial substrate bundle 200 during production.

[0028] In some examples, the idle roller 320 can be replaced with rollers of various weights in order to select the desired force applied to the wound anode-sacrificial substrate bundle 200 during the winding or wrapping process. For example, the idle roller 320 can have a mass of about 5 kg, about 10 kg, or about 15 kg to about 20 kg, about 25 kg, about 30 kg, or more. In one or more examples, the idle roller 320 has a mass of about 5 kg to about 30 kg, about 10 kg to about 20 kg, or about 20 kg to about 30 kg.

[0029] In one or more embodiments, the idle roller 320 may apply a predetermined force to the wound anode-sacrificial substrate bundle 200 during the winding or wrapping process. For example, during the winding or wrapping process, the idle roller 320 may apply a force ranging from about 40 pounds per square inch (PSI), about 50 PSI, about 60 PSI, about 80 PSI, or about 100 PSI to about 120 PSI, about 140 PSI, about 150 PSI, about 160 PSI, about 180 PSI, about 200 PSI, about 220 PSI, about 250 PSI, about 300 PSI, or more to the wound anode-sacrificial substrate bundle 200. In some examples, during the winding or wrapping process, the idle roller 320 can apply about 40PSI to about 300PSI, about 50PSI to about 300PSI, about 80PSI to about 300PSI, about 100PSI to about 300PSI, about 150PSI to about 300PSI, about 200PSI to about 300PSI, about 250PSI to about 300PSI, about 40PSI to about 200PSI, about 50PSI to about 200PSI, or about 150PSI to about 300PSI. I, a force in the range of about 80PSI to about 200PSI, about 100PSI to about 200PSI, about 150PSI to about 200PSI, about 180PSI to about 200PSI, about 40PSI to about 150PSI, about 50PSI to about 150PSI, about 80PSI to about 150PSI, about 100PSI to about 150PSI, or about 120PSI to about 150PSI is applied to the wound anode-sacrificial substrate bundle 200.

[0030] The processing system 100 includes one, two or more heating sources 140, such as infrared lamps, incandescent lamps, or other types of lamps, contained within the processing area 104. Each heating source 140 (e.g., an infrared lamp) can be independently positioned at the sacrificial substrate 110, the anode substrate 120, the wound anode-sacrificial substrate bundle 200, or any combination thereof and direct radiant energy to them. For example, a first heating source 140 can be positioned at the sacrificial substrate 110 between the roller 114 and the rewinding roller 130 and direct radiant energy to the sacrificial substrate 110, a second heating source 140 can be positioned at the anode substrate 120 between the roller 124 and the rewinding roller 130 and direct radiant energy to the anode substrate 120, and a third heating source 140 can be positioned at the wound anode sacrificial substrate bundle 200 on the rewinding roller 130 and direct radiant energy to the anode sacrificial substrate bundle 200.

[0031] One or more thermocouples 142 may also be included in the processing region 104. Each thermocouple 142 may be coupled to a corresponding heating source 140 and may be used to monitor the temperature of the heating source 140 to prevent overheating. In one or more examples, the heating source 140 is a vacuum grade infrared lamp and may be maintained at a processing pressure of less than 760 Torr, for example, about 1×10 - 6 mTorr to about 1×10 -3 For example, the heating source 140 can be maintained at a process pressure of less than 760 Torr for about 24 hours or more, such as greater than 24 hours to about 48 hours, about 26 hours to about 40 hours, about 30 hours to about 36 hours.

[0032] The processing system 100 includes one, two, or more pyrometers 144 contained within the processing area 104. Each pyrometer 144 may be independently positioned to monitor or otherwise receive a temperature of the anode substrate 120 and / or the wound anode-sacrificial substrate bundle 200. For example, a first pyrometer 144 may be positioned at and monitor the temperature of the anode substrate 120 between the roller 124 and the rewind roller 130, and a second pyrometer 144 may be positioned at and monitor the temperature of the wound anode-sacrificial substrate bundle 200 on the rewind roller 130.

[0033] In one or more embodiments, a method for producing or otherwise forming a lithium intercalation anode is provided and includes introducing a sacrificial substrate 110 and an anode substrate 120 into a processing region 104 within a chamber 102. The method also includes overlapping the sacrificial substrate 110 and the anode substrate 120 with each other around a rewinding roller 130 within the processing region 104 during a winding or winding process. The method further includes rotating the rewinding roller 130 to wind the sacrificial substrate 110 and the anode substrate 120 together to produce a wound anode-sacrificial substrate bundle 200 while continuing to introduce the sacrificial substrate 110 and the anode substrate 120 into the processing region 104 during the winding or winding process. The method also includes heating the sacrificial substrate 110, the anode substrate 120, and / or the wound anode-sacrificial substrate bundle 200 while rotating the rewinding roller 130 and applying a force to the wound anode-sacrificial substrate bundle 200 via a deadweight roller or idle roller 320 during the winding or winding process.

[0034] In some examples, the processing region 104 is maintained under vacuum while the sacrificial substrate 110 and the anode substrate 120 are combined and the rewind roller 130 is rotated. For example, the processing region 104 is maintained at a pressure of less than 760 Torr, such as about 1×10 -6 mTorr to about 1×10 -3mTorr, while combining the sacrificial substrate 110 and the anode substrate 120 and rotating the rewind roller 130, and while storing the wound anode-sacrificial substrate bundle 200. In some examples, the processing region 104 is maintained at a pressure of less than 760 Torr, for example, at about 5×10 -7 mTorr, about 1×10 -6 mTorr, about 5×10 -6 millitorr or about 1×10 -5 mTorr to about 5×10 -5 mTorr, about 1×10 -4 mTorr, about 5×10 -4 mTorr, about 1×10 -3 mTorr, about 5×10 -3 mTorr, or about 1×10 -2 The sacrificial substrate 110 and the anode substrate 120 are simultaneously combined and the rewinding roller 130 is rotated under a pressure of 0.1 mTorr, while the wound anode-sacrificial substrate bundle 200 is stored.

[0035] In one or more embodiments, the method further includes transferring at least a portion of the lithium metal from the sacrificial substrate 110 to the anode substrate 120 and absorbing the lithium metal into the anode substrate 120 to produce a lithium intercalated anode substrate.

[0036] In some embodiments, the method includes maintaining the wound anode-sacrificial substrate bundle 200 under vacuum and / or heating for a predetermined time while producing a lithium intercalated anode substrate. The predetermined time or period can be about 1 hour, about 2 hours, about 3 hours, about 5 hours, about 8 hours or about 10 hours to about 12 hours, about 15 hours, about 20 hours, about 24 hours, about 28 hours, about 30 hours, about 36 hours, about 48 hours or longer. For example, the wound anode-sacrificial substrate bundle 200 can be maintained under vacuum and / or heat for a period of time or a period of time from about 1 hour to about 36 hours, from about 2 hours to about 30 hours, from about 2 hours to about 24 hours, from about 2 hours to about 20 hours, from about 2 hours to about 18 hours, from about 2 hours to about 15 hours, from about 2 hours to about 12 hours, from about 2 hours to about 10 hours, from about 2 hours to about 8 hours, from about 2 hours to about 5 hours, from about 2 hours to about 4 hours, from about 4 hours to about 30 hours, from about 5 hours to about 30 hours, from about 8 hours to about 30 hours, from about 10 hours to about 30 hours, from about 12 hours to about 30 hours, from about 15 hours to about 30 hours, from about 18 hours to about 30 hours, from about 20 hours to about 30 hours, from about 24 hours to about 30 hours, or from about 26 hours to about 30 hours while producing a lithium intercalated anode substrate. In other examples, the wound anode-sacrificial substrate bundle 200 is heated under vacuum for a period of time from about 2 hours to about 36 hours, from about 8 hours to about 24 hours, or from about 10 hours to about 18 hours.

[0037] In some embodiments, the wound anode sacrificial substrate bundle 200 is heated and / or maintained at a predetermined temperature by one, two, three or more heat sources 140 (e.g., one or more infrared lamps) located within the processing region 104. In one or more embodiments, each of the sacrificial substrate 110, the anode substrate 120 and / or the wound anode-sacrificial substrate bundle 200 can be independently heated to a predetermined temperature during the winding or wrapping process. The predetermined temperature can be in the range of about 25°C, about 30°C, about 35°C, about 40°C, about 50°C, about 60°C, about 70°C, about 75°C, about 80°C, about 90°C, about 95°C, or about 100°C to about 105°C, about 110°C, about 120°C, about 125°C, about 130°C, about 140°C, about 150°C, about 160°C, about 180°C, about 190°C, about 200°C, about 220°C, about 240°C, about 250°C or about 300°C. For example, during the winding or winding process, each of the sacrificial substrate 110, the anode substrate 120, and / or the wound anode-sacrificial substrate bundle 200 can be independently heated to about 25°C to about 300°C, about 25°C to about 250°C, about 25°C to about 200°C, about 50°C to about 200°C, about 80°C to about 200°C, about 100°C to about 200°C, about 125°C to about 200°C, about 150°C to about 200°C, about 175°C to about 200°C, about 30°C to about 180°C, about 40°C to about 170°C, about 50°C to about 200°C, or about 60°C to about 180°C. A temperature in the range of about 150°C, about 60°C to about 150°C, about 70°C to about 150°C, about 80°C to about 150°C, about 90°C to about 150°C, about 100°C to about 150°C, about 110°C to about 150°C, about 120°C to about 150°C, about 130°C to about 150°C, about 50°C to about 140°C, about 50°C to about 130°C, about 50°C to about 120°C, about 50°C to about 110°C, about 50°C to about 100°C, about 50°C to about 90°C, about 50°C to about 80°C, or about 50°C to about 70°C.

[0038] In other embodiments, the method further includes unwinding the wound anode-sacrificial substrate bundle 200 and separating the lithium intercalated anode substrate from the base foil 108 of the sacrificial substrate 110. The base foil 108 may still include a portion of the lithium coating 111 or lithium metal on the upper surface 108a and the lower surface 108b. Alternatively, the base foil 108 may have no or substantially no lithium coating 111 or lithium metal on the upper surface 108a and the lower surface 108b.

[0039] In one or more embodiments, a method for producing or forming a lithium intercalation anode includes introducing a sacrificial substrate 110 into a processing region 104 within a chamber 102, wherein the sacrificial substrate 110 may be or include a base foil 108 having an upper surface 108a opposite a lower surface 108b and a lithium coating 111 disposed on the upper surface 108a and the lower surface 108b. The method also includes introducing an anode substrate 120 into the processing region 104 within the chamber 102. The method also includes rotating a rewinding roller 130 within the processing region 104 to wind the sacrificial substrate 110 and the anode substrate 120 together and overlap each other to produce a wound anode-sacrificial substrate bundle 200, while continuing to introduce the sacrificial substrate 110 and the anode substrate 120 into the processing region 104 during the winding or wrapping process. When producing the wound anode-sacrificial substrate bundle 200, the processing region 104 is maintained in a vacuum, such as a pressure of less than 760 Torr, such as about 1×10 -6 mTorr to about 1×10 -3 mTorr. The method also includes heating the sacrificial substrate 110, the anode substrate 120 and / or the wound anode-sacrificial substrate bundle 200 while rotating the rewinding roller 130 and applying a force to the wound anode-sacrificial substrate bundle 200 via a deadweight roller or an idle roller 320 during the winding or wrapping process. The method further includes transferring at least a portion of the lithium metal from the sacrificial substrate 110 to the anode substrate 120 while within the wound anode-sacrificial substrate bundle 200, and absorbing the lithium metal into the anode substrate 120 to produce a lithium intercalated anode substrate.

[0040] Embodiments of the present disclosure further relate to any one or more of the following Examples 1-48:

[0041] 1. A method for forming a lithium intercalation anode, comprising: introducing a sacrificial substrate into a processing region within a chamber, wherein the sacrificial substrate comprises a base foil having an upper surface opposite to a lower surface and a lithium coating disposed on the upper surface and the lower surface; introducing an anode substrate comprising graphite into the processing region within the chamber; combining the sacrificial substrate and the anode substrate to overlap each other around a rewinding roller within the processing region during a winding process; rotating the rewinding roller to wind the sacrificial substrate and the anode substrate together to produce a wound anode-sacrificial substrate bundle, while continuing to introduce the sacrificial substrate and the anode substrate into the processing region during the winding process; heating the sacrificial substrate, the anode substrate and / or the wound anode-sacrificial substrate bundle while rotating the rewinding roller during the winding process; applying a force to the wound anode sacrificial substrate bundle via an idle roller during the winding process.

[0042] 2. The method according to Example 1 further comprises: transferring at least a portion of lithium metal from the sacrificial substrate to the anode substrate; absorbing metallic lithium onto the anode substrate to form a lithium intercalated anode substrate.

[0043] 3. The method according to example 1 or 2, further comprising maintaining the wound anode-sacrificial substrate bundle under vacuum for about 2 hours to about 24 hours while producing the lithium intercalated anode substrate.

[0044] 4. The method according to example 1 or 2, further comprising unwinding the wound anode-sacrificial substrate bundle and separating the lithium intercalation anode substrate from the base foil of the sacrificial substrate.

[0045] 5. The method of any one of examples 1-4, wherein the processing area is maintained in vacuum while the sacrificial substrate and the anode substrate are combined and the rewind roller is rotated.

[0046] 6. The method of any one of Examples 1-5, wherein the pressure of the processing area is maintained at about 1×10 -6 mTorr to about 1×10 -3 rewind within the range of mTorr.

[0047] 7. The method of any of Examples 1-6, wherein the sacrificial substrate, the anode substrate, and / or the wound anode-sacrificial substrate bundle is heated to a temperature of about 50° C. to about 200° C. during the winding process.

[0048] 8. The method of any of Examples 1-7, wherein the wound anode-sacrificial substrate bundle is heated under vacuum for a period of time from about 2 hours to about 36 hours.

[0049] 9. The method of any of Examples 1-8, wherein the wound anode-sacrificial substrate bundle is heated by one or more infrared lamps located within the processing region.

[0050] 10. The method of any of examples 1-9, wherein the force applied by the idle roller to the wound anode-sacrificial substrate bundle is from about 80 pounds per square inch (PSI) to about 200 PSI.

[0051] 11. The method according to any one of Examples 1-10, further comprising: when a wound anode-sacrificial substrate bundle is generated from the sacrificial substrate and the anode substrate, moving the idle roller radially away from the rewinding roller; while maintaining the force applied to the wound anode-sacrificial substrate bundle.

[0052] 12. The method of any of Examples 1-11, wherein the chamber comprises a calendering system comprising an idle roller.

[0053] 13. The method of any of Examples 1-12, wherein the calendaring system further comprises two pivot arms, and wherein each pivot arm comprises a slide slot configured to support an idle roller.

[0054] 14. The method of any of Examples 1-13, wherein the calendering system further comprises two casters, wherein each caster is coupled to an opposite end of the idle roller, and wherein each caster is configured to travel within a corresponding slide slot on each pivot arm.

[0055] 15. The method of any of examples 1-14, wherein the base foil of the sacrificial substrate comprises a metal or polymer material.

[0056] 16. The method of any of examples 1-15, wherein the base foil of the sacrificial substrate comprises a metal selected from copper, copper alloys, nickel, nickel alloys, stainless steel alloys, alloys thereof, or any combination thereof.

[0057] 17. The method of any of Examples 1-16, wherein the base foil of the sacrificial substrate comprises a polymer material selected from polyethylene terephthalate (PET), polypropylene (PP), copolymers thereof, elastomers thereof, or any combination thereof.

[0058] 18. The method of any of Examples 1-17, wherein the anode substrate comprises graphite foil, silicon-graphite material, silicon oxide-graphite material, or any combination thereof.

[0059] 19. The method of any of examples 1-18, wherein the rewind roller and the processing area are both in a rewind chamber.

[0060] 20. A method according to any of Examples 1-19, wherein the rewinding chamber is part of a processing system, the processing system also including a processing chamber coupled to the unwinding chamber and the rewinding chamber and located between the unwinding chamber and the rewinding chamber.

[0061] 21. A method for forming a lithium intercalation anode, comprising: introducing a sacrificial substrate into a processing region within a chamber, wherein the sacrificial substrate comprises a base foil having an upper surface opposite to a lower surface and a lithium coating disposed on the upper surface and the lower surface; introducing an anode substrate into the processing region within the chamber; rotating a rewinding roller within the processing region to wind the sacrificial substrate and the anode substrate together and overlap each other to produce a wound anode-sacrificial substrate bundle, while continuing to introduce the sacrificial substrate and the anode substrate into the processing region during the winding process, wherein the processing region is maintained at a pressure of less than 760 Torr when producing the wound anode-sacrificial substrate bundle; heating the sacrificial substrate, the anode substrate and / or the wound anode-sacrificial substrate bundle while rotating the rewinding roller during the winding process; applying a force to the wound anode sacrificial substrate bundle via an idle roller during the winding process; transferring at least a portion of lithium metal from the sacrificial substrate to the anode substrate; absorbing metallic lithium onto the anode substrate to produce a lithium intercalation anode substrate.

[0062] 22. The method of Example 21, wherein the pressure in the processing region is maintained at about 1×10 -6 mTorr to about 1×10 -3 mTorr range.

[0063] 23. The method of example 21 or 22, further comprising maintaining the wound anode-sacrificial substrate bundle under vacuum for about 2 hours to about 24 hours while producing the lithium intercalated anode substrate.

[0064] 24. The method of any of Examples 21-23, further comprising unwinding the wound anode-sacrificial substrate bundle and separating the lithium intercalated anode substrate from the sacrificial substrate.

[0065] 25. The method of any of Examples 21-24, wherein the sacrificial substrate, the anode substrate, and / or the wound anode-sacrificial substrate bundle are heated to a temperature of about 50° C. to about 200° C. during the winding process.

[0066] 26. The method of any of Examples 21-25, wherein the wound anode-sacrificial substrate bundle is heated under vacuum for a time period of about 2 hours to about 36 hours.

[0067] 27. The method of any of Examples 21-26, wherein the wound anode-sacrificial substrate bundle is heated by one or more infrared lamps positioned within the processing region.

[0068] 28. The method of any of Examples 21-27, wherein the force applied by the idle roller to the wound anode-sacrificial substrate bundle is from about 80 pounds per square inch (PSI) to about 200 PSI.

[0069] 29. The method of any one of Examples 21-28, further comprising: when a wound anode-sacrificial substrate bundle is generated from the sacrificial substrate and the anode substrate, moving the idle roller radially away from the rewinding roller; while maintaining the force applied to the wound anode-sacrificial substrate bundle.

[0070] 30. The method of any of Examples 21-29, wherein the chamber comprises a calendering system comprising idle rollers.

[0071] 31. The method of any of Examples 21-30, wherein the calendaring system further comprises two pivot arms, and wherein each pivot arm comprises a slide slot configured to support an idle roller.

[0072] 32. The method of any of Examples 21-31, wherein the calendering system further comprises two casters, wherein each caster is coupled to an opposite end of the idle roller, and wherein each caster is configured to travel within a corresponding slide slot on each pivot arm.

[0073] 33. The method of any of Examples 21-32, wherein the base foil of the sacrificial substrate comprises a metal or polymer material.

[0074] 34. The method of any of Examples 21-33, wherein the base foil of the sacrificial substrate comprises a metal selected from copper, copper alloys, nickel, nickel alloys, stainless steel alloys, alloys thereof, or any combination thereof.

[0075] 35. The method of any of examples 21-34, wherein the base foil of the sacrificial substrate comprises a polymeric material selected from polyethylene terephthalate (PET), polypropylene (PP), copolymers thereof, elastomers thereof, or any combination thereof.

[0076] 36. The method of any of Examples 21-35, wherein the anode substrate comprises graphite foil, a silicon-graphite material, a silicon oxide-graphite material, or any combination thereof.

[0077] 37. The method of any of Examples 21-36, wherein the rewind roller and the processing area are both in a rewind chamber.

[0078] 38. A method according to any of Examples 21-37, wherein the rewinding chamber is part of a processing system, the processing system further comprising a processing chamber coupled to the unwinding chamber and the rewinding chamber and between the unwinding chamber and the rewinding chamber.

[0079] 39. A processing system for forming a lithium intercalation anode, comprising: a chamber having a processing region therein and configured to maintain a pressure in the processing region of about 1×10 -6 mTorr to about 1×10 -3 mTorr range; a first source coupled to the chamber and comprising a sacrificial substrate comprising a base foil having an upper surface opposite to a lower surface and a lithium coating disposed on the upper surface and the lower surface; a second source coupled to the chamber and comprising an anode substrate comprising graphite; a rewind roller disposed in the processing area and configured to receive the sacrificial substrate and the anode substrate and wind them together to produce a wound anode-sacrificial substrate bundle; a calendaring system comprising an idle roller configured to apply a force to the wound anode-sacrificial substrate bundle; one or more infrared lamps contained in the processing area and located at the sacrificial substrate, the anode substrate and / or the wound anode-sacrificial substrate bundle.

[0080] 40. The processing system of example 39, wherein the idle roller is configured to move radially away from the rewind roller while maintaining a force applied to the wound anode-sacrificial substrate bundle as the wound anode-sacrificial substrate bundle is produced from the sacrificial substrate and the anode substrate.

[0081] 41. The processing system of example 39 or 40, wherein the calendering system further comprises two pivot arms, and wherein each pivot arm comprises a slide slot configured to support an idle roller.

[0082] 42 A processing system according to any of Examples 39-41, wherein the calendering system further includes two casters, wherein each caster is coupled to an opposite end of the idle roller, and wherein each caster is configured to travel within a corresponding sliding slot on each pivot arm.

[0083] 43. The processing system of any of examples 39-42, wherein the force applied by the idle roller to the wound anode-sacrificial substrate bundle is from about 80 pounds per square inch (PSI) to about 200 PSI.

[0084] 44. The processing system of any of Examples 39-43, wherein the sacrificial substrate, the anode substrate, and / or the wound anode-sacrificial substrate bundle is heated to a temperature of about 50° C. to about 200° C. during the roll-to-roll processing.

[0085] 45. The processing system of any of Examples 39-44, wherein the rewind roller and the processing area are both in a rewind chamber.

[0086] 46. ​​A processing system according to any of Examples 39-45, wherein the rewinding chamber is part of the processing system, and the processing system further includes a processing chamber coupled to the unwinding chamber and the rewinding chamber and between the unwinding chamber and the rewinding chamber.

[0087] 47. The processing system according to any of Examples 39-45, configured to perform any of the methods of Examples 1-38.

[0088] 48. A processing system configured to implement any of the methods of Examples 1-38.

[0089] Although the foregoing is directed to the embodiments of the present disclosure, other and further embodiments can be designed without departing from its basic scope, and the scope thereof is determined by the appended claims. All documents described herein are incorporated herein by reference, including any priority documents and / or testing procedures that are not inconsistent with this document. It is obvious from the general description and specific embodiments above that although the form of the present disclosure has been illustrated and described, various modifications can be made without departing from the spirit and scope of the present disclosure. Therefore, the present disclosure is not intended to be limited thereby. Similarly, for the purposes of U.S. law, the term "comprising" is deemed to be synonymous with the term "including". Similarly, whenever a composition, element or element group is preceded by the transition phrase "comprising", it should be understood as the same composition or element group with the transition phrase "essentially composed of...", "composed of...", or it is expected that "is" is used before the description of the composition, element or element, and vice versa. As used herein, the term "about" refers to a change of + / -10% from the nominal value. It should be understood that such a change can be included in any value provided herein.

[0090] Certain embodiments and features have been described using a set of numerical minimums and a set of numerical maximums. It should be understood that ranges include combinations of any two values, e.g., unless otherwise specified, combinations of any minimum value with any maximum value, combinations of any two minimum values, and / or combinations of any two maximum values. Certain minimum values, maximum values, and ranges appear in one or more claims below.

Claims

1. A method for forming a lithium intercalation anode, comprising the following steps: introducing a sacrificial substrate into a processing region within the chamber, wherein the sacrificial substrate includes a base foil having an upper surface opposite a lower surface and a lithium coating disposed on the upper surface and the lower surface; introducing an anode substrate comprising graphite into the processing zone within the chamber; During the winding process, the sacrificial substrate and the anode substrate are combined and overlapped with each other in the processing area around a rewinding roller; rotating the rewind roller to wind the sacrificial substrate and the anode substrate together to produce a wound anode-sacrificial substrate bundle while continuing to introduce the sacrificial substrate and the anode substrate into the processing area during the winding process; heating the sacrificial substrate, the anode substrate, and / or the wound anode-sacrificial substrate bundle while rotating the rewind roller during the winding process; and A force is applied to the wound anode sacrificial substrate bundle via an idle roller during the winding process.

2. The method of claim 1, further comprising the steps of: transferring at least a portion of the lithium metal from the sacrificial substrate to the anode substrate; absorbing the lithium metal onto the anode substrate to produce a lithium intercalated anode substrate; and The wound anode-sacrificial substrate bundle is maintained under vacuum for about 2 hours to about 24 hours while producing the lithium intercalated anode substrate.

3. The method of claim 1, further comprising the steps of: transferring at least a portion of the lithium metal from the sacrificial substrate to the anode substrate; absorbing the lithium metal onto the anode substrate to produce a lithium intercalated anode substrate; and The anode-sacrificial substrate bundle is unwound, and the lithium intercalation anode substrate is separated from the base foil of the sacrificial substrate.

4. The method of claim 1, wherein the pressure of the processing area is maintained at about 1×10 -6 mTorr to about 1×10 -3 mTorr range.

5. The method of claim 1, wherein the sacrificial substrate, the anode substrate and / or the wound anode-sacrificial substrate bundle are heated to a temperature of about 50°C to about 200°C during the roll-to-roll process.

6. The method of claim 1, wherein the wound anode-sacrificial substrate bundle is heated under vacuum by one or more infrared lamps positioned within the processing region for a period of about 2 hours to about 36 hours.

7. The method of claim 1, further comprising the steps of: When the wound anode-sacrificial substrate bundle is produced from the sacrificial substrate and the anode substrate, the idle roller is moved radially away from the rewinding roller; The force applied to the wound anode-sacrificial substrate bundle is maintained.

8. The method of claim 1, wherein the chamber comprises a calendering system, the calendering system comprising the idle roller, wherein the calendering system further comprises two pivot arms, and wherein each of the pivot arms comprises a slide slot configured to support the idle roller.

9. The method of claim 8, wherein the calendaring system further comprises two casters, wherein each caster is coupled to opposite ends of the idle roller, and wherein each caster is configured to travel within a corresponding slide slot on each of the pivot arms.

10. The method of claim 1, wherein the base foil of the sacrificial substrate comprises a metal selected from copper, copper alloys, nickel, nickel alloys, stainless steel alloys, alloys thereof, or any combination thereof.

11. The method of claim 1, wherein the base foil of the sacrificial substrate comprises a polymeric material selected from polyethylene terephthalate (PET), polypropylene (PP), copolymers thereof, elastomers thereof, or any combination thereof.

12. The method of claim 1, wherein the anode substrate comprises graphite foil, silicon-graphite material, silicon oxide-graphite material, or any combination thereof.

13. The method of claim 1, wherein the rewinding roller and the processing area are both in a rewinding chamber, wherein the rewinding chamber is part of a processing system, the processing system further comprising a processing chamber coupled to an unwinding chamber and the rewinding chamber and between the unwinding chamber and the rewinding chamber.

14. A method for forming a lithium intercalation anode comprising the following steps: introducing a sacrificial substrate into a processing region within the chamber, wherein the sacrificial substrate includes a base foil having an upper surface opposite a lower surface and a lithium coating disposed on the upper surface and the lower surface; introducing an anode substrate into the processing area within the chamber; rotating a rewinding roller within the processing region to wind the sacrificial substrate and the anode substrate together and overlap each other to produce a wound anode-sacrificial substrate bundle while continuing to introduce the sacrificial substrate and the anode substrate into the processing region during a winding process, wherein the processing region is maintained at a pressure of less than 760 Torr while producing the wound anode-sacrificial substrate bundle; heating the sacrificial substrate, the anode substrate, and / or the wound anode-sacrificial substrate bundle while rotating the rewind roller during the winding process; applying a force to the wound anode sacrificial substrate bundle via an idle roller during the winding process; transferring at least a portion of the lithium metal from the sacrificial substrate to the anode substrate; and The lithium metal is absorbed into the anode substrate to produce a lithium intercalated anode substrate.

15. The method of claim 14, wherein the pressure of the processing region is maintained at about 1×10 -6 mTorr to about 1×10 -3 In the range of millitorr.

16. The method of claim 14, wherein the wound anode-sacrificial substrate bundle is heated under vacuum by one or more infrared lamps positioned within the processing region for a period of about 2 hours to about 36 hours.

17. The method of claim 14, further comprising the steps of: When the wound anode-sacrificial substrate bundle is produced from the sacrificial substrate and the anode substrate, the idle roller is moved radially away from the rewinding roller; The force applied to the wound anode-sacrificial substrate bundle is maintained.

18. The method of claim 14, wherein the chamber comprises a calendering system, the calendering system comprising the idle roller, wherein the calendering system further comprises two pivot arms, and wherein each of the pivot arms comprises a slide slot configured to support the idle roller.

19. The method of claim 14, wherein the rewinding roller and the processing area are both in a rewinding chamber, and wherein the rewinding chamber is part of a processing system, the processing system further comprising a processing chamber coupled to an unwinding chamber and the rewinding chamber and between the unwinding chamber and the rewinding chamber.

20. A processing system for forming a lithium intercalation anode, comprising: A chamber having a processing region therein and configured to maintain the processing region at a temperature from about 1×10 - 6 mTorr to about 1×10 -3 Pressure in the range of mTorr; a first source coupled to the chamber and comprising a sacrificial substrate including a base foil having an upper surface opposite a lower surface and a lithium coating disposed on the upper surface and the lower surface; a second source coupled to the chamber and comprising an anode substrate comprising graphite; a rewind roller disposed within the processing region and configured to receive the sacrificial substrate and the anode substrate and wind the sacrificial substrate and the anode substrate together to produce a wound anode-sacrificial substrate bundle; a calendaring system comprising an idle roller configured to apply a force to the wound anode-sacrificial substrate bundle; and One or more infrared lamps are contained within the processing region and located at the sacrificial substrate, the anode substrate, and / or the wound anode-sacrificial substrate bundle.

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