Molten Lithium Droplet Spraying for Ultra-Thin Foil Thickness Control
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Solution Overview
Problem
Existing manufacturing techniques struggle to produce ultra-thin lithium films below 20 μm with precise thickness control, and existing methods are not suitable for large-area continuous processes.
Innovation Solution
An ultra-thin lithium foil manufacturing apparatus using molten metal droplet spraying, comprising a crucible, nozzle, piezoelectric transducer, and pressurizing pipe, allows for precise thickness control and continuous production of lithium films by ejecting molten lithium through a SUS nozzle plated with copper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cold rolling method is used to manufacture lithium foil, then the mechanical properties are maintained, but the thickness cannot be reduced below 20 μm
Solution Approach 1:
The invention changes the manufacturing method from cold rolling to a new process involving lithium deposition on copper foil substrate. This parameter change enables thickness reduction below 20 μm while maintaining mechanical integrity through the composite structure of lithium-copper foil
Solution Approach 2:
The invention creates a composite structure by depositing lithium metal onto a copper foil substrate. This composite approach allows the lithium layer to be extremely thin (below 20 μm) while the copper substrate provides the necessary mechanical strength and handling properties
2Manufacturing precision
If molten lithium infiltration method is used, then thickness control is improved, but large-area continuous production is not achievable
Solution Approach 1:
The invention implements continuous production by continuously moving the copper foil substrate through the lithium deposition process. The substrate is fed from a roll and wound onto another roll, enabling large-area continuous manufacturing while maintaining precise thickness control through controlled lithium deposition
3Quantity of substance
If lithium metal anode is used to achieve high specific capacity, then battery capacity is improved, but dendrite formation causes safety issues
Solution Approach 1:
The invention applies local quality by creating a uniform, controlled lithium layer on the copper foil substrate. This controlled local deposition prevents the random dendrite formation that occurs in bulk lithium metal anodes, maintaining high lithium content while ensuring safety through uniform distribution
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
Enables the production of thinner lithium films with precise thickness control and supports continuous manufacturing processes, applicable to various substrates.
Implementation Method 1
a piezoelectric transducer installed at the other end of the crucible to transmit an excitation force to the molten metal in the crucible at a frequency set by a function generator
Implementation Method 2
a pressurizing pipe coupled to the crucible to transmit a pressurizing force to the molten metal
Implementation Method 3
a crucible configured to apply heat to molten metal supplied from an external source to maintain a molten state of metal
Data Source
AI summary
An ultra-thin lithium foil manufacturing apparatus includes: a crucible configured to apply heat to molten metal supplied from an external source to maintain a molten state of metal; a nozzle portion installed at one end of the crucible to eject the molten metal; a piezoelectric transducer installed at the other end of the crucible to transmit an excitation force to the molten metal in the crucible at a frequency set by a function generator; and a pressurizing pipe coupled to the crucible to transmit a pressurizing force to the molten metal. The crucible and the nozzle portion move within a set range while the molten metal is ejected through the nozzle portion. The present invention provides an ultra-thin lithium foil manufacturing apparatus using molten metal droplet spraying capable of manufacturing thinner lithium films beyond the thickness limitations of existing manufacturing techniques.