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.

What is claimed: 
     
         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 having a mean particle size of 60 microns or less onto a carrier to a thickness of 20 microns or less to form a single layer;   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) subjecting the substrate while in contact with the carrier to conditions sufficient to transfer the stabilized lithium metal powder 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.   
     
     
         2 . The method of  claim 1 , wherein the carrier is an amorphous solid resin, cellulosic or metallic, 
     
     
         3 . 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. 
     
     
         4 . The method of  claim 1 , wherein in step (c), the conditions sufficient to transfer the lithium metal comprises pressing the carrier and substrate together. 
     
     
         5 . The method of  claim 2 , 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.