Double-Sided Lithium Metal Anodes for Wide Continuous Fabrication
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Solution Overview
Problem
The existing methods for fabricating lithium metal anodes are limited by the width of the extruded lithium foils, which typically do not exceed 100 to 150 millimeters, restricting the size of the anodes that can be produced.
Innovation Solution
A method involving thermal evaporation of lithium to form continuous lithium layers on polymer substrates, which are then laminated onto a metallic substrate to create a continuous lithium/metal/lithium anode structure, allowing for wider anodes beyond the limitations of traditional foil-based methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If extruded lithium foil is used to fabricate lithium metal anodes, then the fabrication process is simple and straightforward, but the width of the anodes is limited to a maximum of about 100 to 150 millimeters
Solution Approach 1:
The patent divides the wide anode fabrication into multiple narrower extruded lithium foils (e.g., three 100mm foils to create a 300mm wide anode). Each foil is extruded separately using existing equipment limitations, then joined together through lamination to achieve the desired wide configuration without requiring a single large extrusion operation.
Solution Approach 2:
The patent combines multiple extruded lithium foils with a metallic substrate through lamination to create a wider composite anode structure. The foils are laminated onto the substrate in a specific sequence and configuration, merging multiple components into a unified wide anode that exceeds the capability of single extrusion processes.
2Length of stationary object
If larger lithium ingots are used to increase anode width, then the anode width limitation is overcome, but the equipment size and manufacturing complexity increase significantly
Solution Approach 1:
Instead of using one large lithium ingot that would require oversized extrusion equipment, the patent segments the lithium into multiple smaller ingots that can be extruded with existing equipment. Each smaller ingot produces a narrower foil that is then combined with others to achieve the target width without needing larger equipment.
Solution Approach 2:
The patent changes the approach from increasing ingot size to increasing the number of ingots. By maintaining the extrusion parameters within existing equipment capabilities and parallelizing the process through multiple foils, the desired width is achieved without modifying equipment size or complexity.
3Length of stationary object
If multiple narrow lithium foils are laminated together to increase anode width, then the anode width exceeds equipment limitations, but the manufacturing process becomes more complex
Solution Approach 1:
The patent performs preliminary actions by extruding and preparing multiple lithium foils separately with consistent properties before lamination. This includes controlling the extrusion parameters, thickness, and quality of each foil individually, so that when they are laminated together, the process is streamlined and the final wide anode has uniform characteristics.
Solution Approach 2:
The patent uses a metallic substrate as an intermediary carrier during the lamination process. The narrow lithium foils are laminated onto the substrate which provides structural support and facilitates handling of the wide composite structure. This intermediary enables the manufacturing process to manage the complexity of working with multiple foils by providing a stable base.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of continuous lithium metal anodes with widths greater than 200 millimeters, potentially up to 1 meter, overcoming the size limitations of traditional methods and expanding the possibilities for lithium metal anode applications.
Implementation Method 1
thermally evaporating lithium to form first and second continuous lithium layers on respective first and second continuous polymer substrates
Implementation Method 2
laminating the first and second continuous lithium/polymer sheets onto respective top and bottom surfaces of a continuous metallic substrate
Data Source
AI summary
A method for fabricating wide and continuous double-sided lithium metal anodes includes thermally evaporating lithium to form first and second continuous lithium layers on respective first and second continuous polymer substrates, so as to form respective first and second continuous lithium/polymer sheets. The first and second continuous lithium/polymer sheets are laminated onto respective top and bottom surfaces of a continuous metallic substrate, which may be made of copper, with the first and second continuous lithium layers being disposed in direct contact with the respective top and bottom surfaces to form a continuous polymer/lithium/metal/lithium/polymer structure. The first and second continuous polymer substrates are then removed from the continuous polymer/lithium/metal/lithium/polymer structure to provide a continuous lithium/metal/lithium anode structure. Each of the first and second continuous lithium layers may be at least 200 millimeters wide, and may cover an entire respective width of the respective first and second continuous polymer substrates.