Inline Anode Pre-Lithiation by Contact Calendering

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Solution Overview

Problem

Existing pre-lithiation methods for Li-ion batteries, such as chemical and electrochemical pre-lithiation, have long reaction times and safety risks, making them unsuitable for volume manufacturing, and silicon-blended graphite anodes suffer from first cycle irreversible capacity loss due to active lithium loss during the first cycle charge.

Innovation Solution

A method involving direct contact calendering of a lithium metal layer with a prefabricated electrode using a carrier substrate, applying pressure and optionally heating, to pre-lithiate the anode material efficiently and safely, suitable for continuous web processing systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If chemical or electrochemical pre-lithiation methods are used, then active lithium loss is compensated, but reaction time is long and safety risks increase

Engineering Contradiction:

Improveactive lithium loss compensationVSAvoidreaction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent extracts the pre-lithiation function from complex chemical or electrochemical processes and implements it through a simple physical contact mechanism. A lithium-containing layer is applied directly to the anode surface, eliminating the need for lengthy chemical reactions or electrochemical cycles while achieving the same lithium compensation effect.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces chemical and electrochemical processes with a mechanical application method. The lithium-containing layer is physically applied to the anode through coating or lamination techniques, substituting complex chemical reactions with a straightforward mechanical process that is faster and safer.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Use of energy by moving object

If silicon-blended graphite anodes are used, then energy cell density increases, but first cycle irreversible capacity loss increases

Engineering Contradiction:

Improveenergy cell densityVSAvoidactive lithium loss

Core Design Contradiction:

Use of energy by moving objectVSLoss of substance

Solution Approach 1:

The patent applies preliminary action by pre-coating the anode with a lithium-containing layer before battery assembly and first charge cycle. This pre-lithiation compensates for the lithium that will be lost during SEI formation, ensuring that silicon-blended graphite anodes can achieve their full energy density potential without suffering from first cycle capacity loss.

Inventive Principle:

Principle #10Preliminary action

3Use of energy by moving object

If pre-lithiation is performed to compensate active lithium loss, then energy density improves, but manufacturing complexity increases

Engineering Contradiction:

Improveenergy densityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent merges the pre-lithiation step with the existing anode fabrication process. The lithium-containing layer is applied during the same manufacturing operations used for anode coating or assembly, combining multiple functions into a single integrated process that does not add significant manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

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 enhances Li-ion battery energy density, reduces cathodic coating loading, and improves mechanical stability of silicon-based anodes, offering safer and more efficient pre-lithiation suitable for high-performance batteries.

Implementation Method 1

contacting a surface of the layer of anode material with a surface of the layer of lithium metal

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

calendering the layer of lithium metal and the prefabricated electrode together

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

heating at least one of the carrier substrate comprising the layer of lithium metal or the prefabricated electrode to a temperature

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS12463194B2Inline contact pre-lithiation

Publication Date: 2025.11.04 ELEVATED MATERIALS US LLC

AI summary

A method and system for fabricating a pre-lithiated electrode structure are provided. The method includes supplying a first continuous web substrate from an unwinder roller to a winder roller. The first continuous web substrate includes a layer of lithium metal. The method further includes supplying a second continuous web substrate comprising a layer of patterned anode material adjacent to the first continuous web substrate. The first continuous web substrate and the second continuous web substrate are wound together on the unwinder roller, wherein a surface of the layer of anode material contacts a surface of the layer of lithium metal. Pressure is applied to the first continuous web substrate and the second continuous web substrate to pre-lithiate the patterned anode material, wherein applying pressure comprises tensioning at least one of the unwinder roller and the winder roller.