Sublimating Release Layer for Clean Alkali Metal Film Transfer

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional methods for transferring thin film lithium in energy storage devices suffer from low throughput and challenges in depositing lithium of different sizes over substrates, often resulting in residual release layers that impede ion or electronic transport.

Innovation Solution

A method using a release layer with a low sublimation point, such as hexo-Fluro-isopropoxide (LiHFIP) or lithium Nona-Fluoro-Tertbutoxide (LiNFTB), is employed to transfer lithium from a polymer substrate to a carrier substrate via sublimation, allowing for clean transfer and patterning of the alkali metal layer without residual release layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional release layers are used to transfer thin film lithium, then the transfer process can be completed, but residual release layer material remains and impedes ion or electronic transport

Engineering Contradiction:

Improveion or electronic transportVSAvoidresidual release layer material

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent employs a release layer material that undergoes phase transition from solid to gas (sublimation) when exposed to specific wavelength light. This phase transition allows the release layer to completely evaporate after transferring the lithium film, eliminating residual material that would otherwise impede ion or electronic transport in the energy storage device.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent replaces conventional thermal heating methods with optical irradiation using specific wavelength light sources. This substitution allows for more precise and complete sublimation of the release layer material, ensuring complete removal without leaving residues that would affect device performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If conventional roll-to-roll processing is used, then lithium transfer can be achieved, but throughput is low and depositing lithium of different sizes is challenging

Engineering Contradiction:

ImprovethroughputVSAvoiddepositing lithium of different sizes

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent employs a flexible substrate that can be dynamically shaped or folded into different configurations before the lithium deposition and transfer process. This flexibility allows the same continuous roll-to-roll processing system to accommodate lithium films of different sizes and shapes without requiring complex reconfiguration of the processing equipment, thereby maintaining high throughput while enabling size customization.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent divides the lithium transfer process into distinct sequential steps: (1) depositing lithium on the flexible substrate, (2) folding or shaping the substrate into the desired configuration, (3) transferring the lithium to the final destination, and (4) releasing the lithium. This segmentation allows for flexible size customization at the folding step while maintaining efficient continuous processing through the other steps.

Inventive Principle:

Principle #1Segmentation

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

The method enables efficient, high-throughput transfer of lithium with minimal residual material, improving the quality of the alkali metal layer and enabling customization of sizes and patterns suitable for energy storage devices.

Implementation Method 1

the release layer including a low sublimation point, wherein the low sublimation point is less than 120° C., sublimating the release layer via a treatment source to transfer the alkali metal layer

Methodology Applied

Scientific EffectSublimation: Sublimation

Implementation Method 2

sublimating the release layer via a treatment source to transfer the alkali metal layer from the flexible substrate to the first flexible carrier

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20260061734A1Metal or alloy film release by low sublimation release layer for electrochemical device

Publication Date: 2026.03.05 ELEVATED MATERIALS US LLC

AI summary

Embodiments of the present disclosure relate to methods and devices related to thin film alkali metal energy storage devices. The method for transferring an alkali metal layer includes disposing a release layer over a flexible substrate, the release layer including a low sublimation point, wherein the low sublimation point is less than 120° C., disposing the alkali metal layer onto the release layer, laminating the release layer and the alkali metal layer between the flexible substrate and a first flexible carrier, sublimating the release layer via a treatment source to transfer the alkali metal layer from the flexible substrate to the first flexible carrier, the treatment source operable to pattern the alkali metal layer, and peeling away the flexible substrate from the first flexible carrier.