Lithium Anode Interlayer for Uniform Plating and Stripping

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Solution Overview

Problem

Current manufacturing methods for alkali metal anodes in energy storage devices face challenges in achieving uniform plating and stripping, leading to internal shorts and thermal runaway, and there is a lack of a simple manufacturing path for producing such devices.

Innovation Solution

The implementation of a constriction compliant plating and stripping enhancement film, which can be produced using vacuum or atmospheric coating techniques, is integrated into the anode structure to facilitate uniform lithium plating and stripping, utilizing a substrate-independent direct transfer process for high-volume manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional manufacturing methods are used for alkali metal anodes, then production can proceed with existing processes, but uniform plating and stripping cannot be achieved, leading to internal shorts and thermal runaway

Engineering Contradiction:

Improvecycling performance and stabilityVSAvoiduniformity of plating and stripping

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

A plating and stripping enhancement film is introduced as an intermediary layer between the alkali metal-containing film and the current collector. This enhancement film comprises a constriction compliant material that mediates the interface interactions, enabling uniform lithium plating and stripping while preventing internal shorts and thermal runaway events.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The constriction compliant material in the enhancement film undergoes parameter changes (constriction and expansion) in response to volume changes of the alkali metal during cycling. This dynamic parameter adjustment maintains uniform contact and pressure distribution, ensuring consistent plating and stripping performance across cycles.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If a plating and stripping enhancement film with constriction compliant material is implemented, then uniform lithium plating and stripping can be achieved, but device complexity increases

Engineering Contradiction:

Improveuniformity of plating and strippingVSAvoidanode structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The anode is segmented into distinct functional layers: the plating and stripping enhancement film as a separate intermediate layer, and the alkali metal-containing film as the active material layer. This segmentation allows each layer to perform its specific function independently, simplifying the design and manufacturing process despite the added layer.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The plating and stripping enhancement film serves multiple functions simultaneously: it provides a uniform interface for plating and stripping, accommodates volume changes through constriction compliant material, and prevents internal shorts. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If substrate-independent direct transfer process is used for high-volume manufacturing, then productivity increases, but manufacturing precision may be compromised

Engineering Contradiction:

Improvehigh-volume manufacturing capabilityVSAvoidfilm transfer accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The plating and stripping enhancement film is formed on the carrier substrate before the alkali metal-containing film is transferred. This preliminary action ensures that the enhancement film is already in place to provide uniform plating and stripping functionality, and the substrate-independent direct transfer process can proceed without compromising precision, as the critical interface is already prepared.

Inventive Principle:

Principle #10Preliminary action

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 approach enables the production of alkali-metal anodes with improved cycling performance and stability, reducing the risk of internal shorts and enabling high-capacity energy storage devices.

Implementation Method 1

a plating and stripping enhancement film over the carrier substrate, the plating and stripping enhancement film comprising a constriction compliant material

Methodology Applied

Scientific EffectConstriction compliant material deformation: Elasticity

Implementation Method 2

forming an alkali metal-containing film on the plating and stripping enhancement film

Methodology Applied

Scientific EffectVacuum deposition: Physical Vapour Deposition

Data Source

PatentUS20250337020A1Alkali metal or alloy anode with uniform li plating and stripping interlayer

Publication Date: 2025.10.30 ELEVATED MATERIALS US LLC

AI summary

Anode film stacks incorporating a constriction susceptible interlayer or a plating and stripping enhancement layer are provided. The anode film stack enables production of alkali-metal anodes or alkali metal alloy anodes with uniform Li plating and stripping performance, which can be used in an energy storage devices, for example, a battery or a capacitor. Methods and systems for forming the anode film stack are also provided.