Layered Lithium Anode Structure for Uniform Plating Stability

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Solution Overview

Problem

Existing lithium-ion batteries face challenges in achieving uniform current distribution and mechanical stability due to the use of rough surfaces in conventional anode designs, which can lead to lithium film fracture and exposure.

Innovation Solution

The anode structure includes a plating layer with a uniformly plated lithium layer, optionally supported by a support and capping layer, and bonded via a bonding layer, allowing for uniform lithium distribution and mechanical robustness, enabling current flow in the z-direction without tabs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional rough film or foil is used in stacked designs, then the anode structure is simpler to manufacture, but the surface roughness causes lithium film fracture, dissolution, and exposure

Engineering Contradiction:

Improvelithium film stabilityVSAvoidanode structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The anode is segmented into multiple functional layers: a support layer (e.g., aluminum foil), a plating layer (e.g., copper or titanium), and a lithium layer. This segmentation allows each layer to perform its specific function - the support layer provides mechanical strength, the plating layer provides a uniform surface for lithium deposition, and the lithium layer stores energy, thereby preventing lithium film fracture while maintaining structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The anode uses a composite structure combining different materials with complementary properties. The support layer (aluminum) provides mechanical stability, the plating layer (copper/titanium) provides a smooth surface for uniform lithium plating, and the lithium layer provides energy storage. This composite approach resolves the contradiction by combining materials that individually address different requirements.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If a conventional rough surface is used, then the manufacturing process is simpler, but uniform current distribution cannot be achieved

Engineering Contradiction:

Improveuniformity of lithium distributionVSAvoidanode fabrication difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The plating layer is deposited on the support layer before lithium plating occurs. This preliminary action creates a uniform, smooth surface that ensures even current distribution during subsequent lithium deposition, preventing the formation of dendrites and ensuring uniform lithium distribution throughout the anode structure.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The plating layer is specifically designed with local qualities different from the support layer - it has a smoother surface and different electrical properties optimized for lithium deposition. This local quality enhancement at the lithium-facing surface ensures uniform current distribution without requiring the entire anode structure to be complex.

Inventive Principle:

Principle #3Local quality

3Quantity of substance

If lithium film is plated on rough surface, then energy storage capacity increases, but mechanical stability decreases due to fracture and dissolution

Engineering Contradiction:

Improvelithium contentVSAvoidmechanical stability

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The plating layer acts as an intermediary between the support layer and the lithium layer. It provides a controlled interface that allows high lithium content to be achieved while maintaining mechanical stability. The plating layer's smooth surface ensures uniform lithium distribution, preventing stress concentrations that would lead to fracture, while its adhesion properties prevent dissolution.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 design ensures uniform lithium distribution, mechanical robustness, and efficient energy storage in a compact form, facilitating the stacking of battery cells while preventing lithium exposure and enhancing the battery's overall performance.

Implementation Method 1

The lithium layer can be disposed on the surface of the plating layer, for example by sputtering, electron beam deposition, or chemical vapor deposition

Methodology Applied

Scientific EffectSputtering: Sputtering

Implementation Method 2

The lithium layer can be disposed on the surface of the plating layer, for example by sputtering, electron beam deposition, or chemical vapor deposition

Methodology Applied

Scientific EffectElectron beam deposition:

Implementation Method 3

The lithium layer can be disposed on the surface of the plating layer, for example by sputtering, electron beam deposition, or chemical vapor deposition

Methodology Applied

Scientific EffectChemical vapor deposition: Chemical Vapour Deposition

Data Source

PatentUS20250183260A1Anodes and anode structures

Publication Date: 2025.06.05 APPLE INC

AI summary

Anodes including a plating layer and a lithium plated layer, and optionally a support layer, capping layer, and bonding layer, are described.