Finely deposited lithium metal powder

Abstract

The present invention provides a method of finely depositing lithium foil onto a substrate while avoiding the use of a solvent. The method includes depositing lithium foil onto a carrier, contacting the carrier with a substrate having a higher affinity for the lithium metal powder as compared to the affinity of the carrier for the lithium metal powder, subjecting the substrate while in contact with the carrier to conditions sufficient to transfer the lithium foil deposited on the carrier to the substrate, and separating the carrier and substrate so as to maintain the lithium metal foil, deposited on the substrate.

1 . A method of depositing lithium metal powder onto a substrate without the use of a solvent, said method consisting essentially of the steps of:
 a) depositing stabilized lithium metal powder onto a carrier to form a foil layer, wherein the carrier has an affinity for the lithium metal powder;   b) contacting the carrier with a substrate having a higher affinity for the lithium metal powder as compared to the affinity of the carrier for the stabilized lithium metal powder;   c) adhering the stabilized lithium metal powder foil layer deposited on the carrier to the substrate; and   d) separating the carrier and substrate so as to maintain the stabilized lithium metal powder deposited on the substrate as a foil layer.   
     
     
         2 . The method of  claim 1 , wherein the substrate is a material selected from the group consisting of carbonaceous materials, Li 4 Ti 5 O 12 , Si, Sn, Cu, SiO, tin oxides, tin alloys, metal foils, conductive polymers, conductive ceramics, transition metal oxides, lithium metal nitrides, lithium metal oxides, and mixtures or composites thereof. 
     
     
         3 . The method of  claim 1 , wherein the carrier comprises a separator material selected from an amorphous solid resin, glass, or metallic separator material. 
     
     
         4 . The method of  claim 3 , wherein the amorphous solid resin is selected from polypropylene, polyethylene, polyester or a combination hereof. 
     
     
         5 . The method of  claim 3 , wherein the metallic separator material is a metal foil. 
     
     
         6 . The method of  claim 1  further including applying a binder to the carrier, wherein the stabilized lithium metal powder is electrostatically deposited onto the carrier. 
     
     
         7 . The method of  claim 1 , wherein the step of depositing stabilized lithium metal powder onto the carrier is selected from sieving, spraying, coating, printing, painting, or dipping stabilized lithium metal powder onto the carrier. 
     
     
         8 . The method of  claim 1 , wherein the step of depositing stabilized lithium metal powder onto the carrier is selected from depositing the stabilized lithium metal powder onto the carrier using high pressure vapor flow technology or gas flow technology. 
     
     
         9 . The method of  claim 1 , wherein the foil layer has a thickness of less than 20 microns. 
     
     
         10 . The method of  claim 1 , wherein the carrier has a thickness of 10 microns to 200 microns.