Finely deposited lithium metal powder

Abstract

The present invention provides a method of finely depositing lithium metal powder or thin lithium foil onto a substrate while avoiding the use of a solvent. The method includes depositing lithium metal powder or thin 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 metal powder or lithium foil deposited on the carrier to the substrate, and separating the carrier and substrate so as to maintain the lithium metal powder or lithium metal foil, deposited on the substrate.

1 . A method of finely depositing lithium metal powder onto a substrate without the use of a solvent, said method comprising:
 a) depositing lithium metal powder onto a carrier;   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 lithium metal powder;   c) subjecting the substrate while in contact with the carrier to conditions sufficient to transfer the lithium metal powder deposited on the carrier to the substrate; and   d) separating the carrier and substrate so as to maintain the lithium metal powder finely deposited on the substrate.   
     
     
         2 . The method of  claim 1 , wherein the lithium metal powder is stabilized lithium metal powder. 
     
     
         3 . The method of  claim 1 , wherein the carrier is a synthetic or semi-synthetic amorphous solid resin, cellulosic or metallic. 
     
     
         4 . The method of  claim 1 , wherein the substrate is contacted with an affinity promoting agent prior to contact with the carrier. 
     
     
         5 . 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, and lithium metal oxides, and mixtures or composites thereof. 
     
     
         6 . The method of  claim 1 , wherein in step (c), the conditions sufficient to transfer the lithium metal comprises pressing the carrier and substrate together. 
     
     
         7 . The method of  claim 4 , 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, and lithium metal oxides, and mixtures or composites thereof. 
     
     
         8 . A method of finely depositing lithium metal powder onto a substrate without the use of a solvent, said method comprising:
 a) depositing lithium metal powder derived foil onto a carrier;   b) contacting the carrier with a substrate having a higher affinity for the lithium metal powder of the foil as compared to the affinity of the carrier for the lithium metal powder of the foil;   c) subjecting the substrate while in contact with the carrier to conditions sufficient to transfer the lithium metal powder foil deposited on the carrier to the substrate; and   d) separating the carrier and substrate so as to maintain the lithium metal powder foil deposited on the substrate.   
     
     
         9 . The method of  claim 8 , wherein the lithium metal powder is stabilized lithium metal powder. 
     
     
         10 . The method of  claim 8 , wherein the carrier is a synthetic or semi-synthetic amorphous solid resin, cellulosic or metallic. 
     
     
         11 . The method of  claim 8 , wherein the substrate is contacted with an affinity promoting agent prior to contact with the carrier. 
     
     
         12 . The method of  claim 11 , 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, and lithium metal oxides, and mixtures or composites thereof. 
     
     
         13 . The method of  claim 8 , wherein in step (c), the conditions sufficient to transfer the lithium metal comprises pressing the carrier and substrate together. 
     
     
         14 . A lithium carrier for depositing a lithium metal powder onto a substrate without the use of a solvent, said lithium carrier comprising a carrier and lithium metal powder deposited thereon, wherein the carrier affinity for the lithium metal powder is less than the lithium metal powder affinity for the substrate. 
     
     
         15 . The lithium carrier according to  claim 14 , wherein the lithium metal powder is stabilized lithium metal powder. 
     
     
         16 . A lithium carrier for depositing a lithium metal powder onto a substrate without the use of a solvent, said lithium carrier comprising a carrier and a thin lithium metal foil deposited thereon, wherein the carrier affinity for the lithium metal of the thin lithium metal foil is less than the lithium metal affinity for the substrate. 
     
     
         17 . A method for forming a battery comprising:
 a) forming an electrode from a material selected from the group consisting of carbonaceous materials, Li 4 Ti 5 O 12 , Si, Sn, SiO, tin oxides, tin alloys, metal foils, conductive polymers, conductive ceramics, transition metal alloys, lithium metal nitrides, and lithium metal oxides and mixtures and composites thereof;   b) contacting the surface of the electrode with a lithium carrier comprising a carrier material and lithium metal deposited thereon wherein the carrier affinity for the lithium metal powder is less than the lithium metal powder affinity for the electrode material;   c) removing the carrier from the electrode wherein the lithium metal powder is deposited on a surface of the electrode; and   d) using the electrode with the lithium metal deposited thereon as a negative electrode (anode) in the formation of a battery.