Printable Lithium Foil Composition for Thin Anodes and Dendrite Control

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Solution Overview

Problem

There is a need for thinner lithium foils and films for lithium-ion cells and other lithium metal batteries with improved electrochemical performances, as existing technologies face challenges with dendrite growth and irreversible capacity loss.

Innovation Solution

A printable lithium composition comprising lithium metal powder, a polymer binder, and a rheology modifier, such as carbon nanotubes, is used to form foils or films with a laminated thickness between 1 micron and 50 microns, enhancing electrochemical performance and reducing dendrite growth.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If lithium metal powder is used to form thin foils and films, then electrochemical performance is improved and dendrite growth is reduced, but manufacturing complexity increases due to the need for polymer binders and rheology modifiers

Engineering Contradiction:

Improvedendrite growth preventionVSAvoidcomposition complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining lithium metal powder with polymer binders and rheology modifiers to create a printable composition. This composite approach allows the formation of thin foils and films that maintain structural integrity while preventing dendrite growth, resolving the contradiction between reliability improvement and manufacturing complexity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent utilizes parameter changes by controlling the thickness of the lithium foil to between 1-50 microns and adjusting the composition ratios of lithium metal powder, polymer binder, and rheology modifier. These parameter optimizations enable improved electrochemical performance and dendrite prevention while managing the complexity of the multi-component system.

Inventive Principle:

Principle #35Parameter changes

2Weight of moving object

If foil thickness is reduced to improve battery performance, then energy density increases, but mechanical strength and stability deteriorate

Engineering Contradiction:

Improvefoil thicknessVSAvoidmechanical stability

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent employs composite materials by integrating polymer binders and rheology modifiers with lithium metal powder. This composite structure provides mechanical support to the thin foil (1-50 microns), enabling reduced thickness while maintaining adequate mechanical strength and stability during battery operation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by creating a multi-phase composite where different components serve specific functions: lithium metal powder provides electrochemical activity, polymer binder provides structural cohesion, and rheology modifier provides flow control and mechanical reinforcement. This localized functional distribution allows thin foils to achieve both reduced weight and maintained strength.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If polymer binder and rheology modifier are added to the lithium composition, then printability and coating uniformity improve, but the composition complexity and processing difficulty increase

Engineering Contradiction:

Improvecoating uniformityVSAvoidcomposition complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by optimizing the ratios of lithium metal powder, polymer binder, and rheology modifier, as well as controlling processing parameters such as coating thickness (1-50 microns) and curing conditions. These parameter optimizations enable uniform coating deposition while managing the complexity of the multi-component composition.

Inventive Principle:

Principle #35Parameter changes

4Use of energy by moving object

If conventional lithium metal anode is used, then high specific capacity is achieved, but dendrite formation occurs causing unsafe conditions

Engineering Contradiction:

Improvespecific capacityVSAvoiddendrite formation

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent resolves the contradiction between high specific capacity and dendrite prevention by creating a composite lithium anode consisting of lithium metal powder dispersed in a polymer binder matrix with rheology modifiers. This composite structure maintains the high capacity of lithium metal while the polymer and rheology modifier components suppress dendrite formation, enabling safe operation.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12341199B2Printed lithium foil and film

Publication Date: 2025.06.24 LIVENT USA CORP

AI summary

A substrate coated with a printable lithium composition is provided. The printable lithium composition includes lithium metal powder; a polymer binder, wherein the polymer binder is compatible with the lithium powder; and a rheology modifier compatible with the lithium powder and the polymer binder, wherein the rheology modifier is dispersible within the composition and provides a three-dimensional support structure for further improvement of the electrochemical performance of the electrode when coated with the composition. The substrate may be incorporated into a battery. In one embodiment, the battery comprises a cathode, an electrolyte and an anode, wherein the cathode, the electrolyte, the separator, the anode, or a combination thereof may each comprise a substrate coated with a printable lithium composition.