Method of manufacturing an anode structure, vacuum deposition system, anode structure, and lithium battery layer stack

Abstract

A method of manufacturing an anode structure (10) for a lithium battery is described. The method includes a first deposition of lithium on a first flexible support (21) to provide a lithium anode-first sublayer (12-1) with a first lithium surface (31); a second deposition of lithium on a second flexible support (22) to provide a lithium anode-second sublayer (12-2) with a second lithium surface (32); and combining the lithium anode-first sublayer (12-1) and the lithium anode-second sublayer (12-2) by pressing the first lithium surface and the second lithium surface together to form a lithium metal anode layer (12). Further described are a lithium battery layer stack with an anode structure manufactured according to the described method, and a vacuum deposition system for manufacturing an anode structure as described herein.

1 . A vacuum deposition system for manufacturing an anode structure, comprising:
 a first lithium deposition apparatus for depositing a lithium anode-first sublayer with a first lithium surface on a first flexible support;   a second lithium deposition apparatus for depositing a lithium anode-second sublayer with a second lithium surface on a second flexible support; and   a combining device for combining the lithium anode-first sublayer and the lithium anode-second sublayer by pressing the first lithium surface and the second lithium surface together to form a lithium metal anode layer.   
     
     
         2 . The vacuum deposition system of  claim 1 ,
 wherein the first lithium deposition apparatus comprises a first coating drum configured for guiding the first flexible support past one or more first lithium evaporators in a first vacuum deposition chamber,   and the second lithium deposition apparatus comprises a second coating drum configured for guiding the second flexible support past one or more second lithium evaporators in a second vacuum deposition chamber.   
     
     
         3 . The vacuum deposition system of  claim 2 , further comprising a vacuum combination chamber between the first vacuum deposition chamber and the second vacuum deposition chamber and having the combining device arranged therein. 
     
     
         4 . The vacuum deposition system of  claim 2 , further comprising
 a first web transportation system configured for transporting the first flexible support from a first unwinding roll to the first coating drum and from the first coating drum to the combining device, and   a second web transportation system configured for transporting the second flexible support from a second unwinding roll to the second coating drum and from the second coating drum to the combining device, such that the first lithium surface and the second lithium surface face each other in the combining device and can be brought in direct contact by the combining device.   
     
     
         5 . The vacuum deposition system of  claim 1 , wherein the combining device comprises a first press roll biased toward a second press roll, such that the first flexible support with the lithium anode-first sublayer and the second flexible support with the lithium anode-second sublayer can be guided between and pressed together by the first and the second press rolls. 
     
     
         6 . An anode structure, manufactured by:
 a first deposition of lithium on a first flexible support to provide a lithium anode-first sublayer with a first lithium surface;   a second deposition of lithium on a second flexible support to provide a lithium anode-second sublayer with a second lithium surface; and   combining the lithium anode-first sublayer and the lithium anode-second sublayer by pressing the first lithium surface and the second lithium surface together to form a lithium metal anode layer.   
     
     
         7 . A lithium battery layer stack, comprising:
 a cathode current collector,   a cathode on the cathode current collector,   a separator or a solid state electrolyte layer on the cathode current collector,   a lithium metal anode layer on the separator or solid state electrolyte layer, and   an anode current collector on the lithium metal anode layer,   wherein the lithium metal anode layer is a lithium film in direct contact with both the anode current collector and the separator or solid state electrolyte layer.   
     
     
         8 . The lithium battery layer stack of  claim 7 , wherein a first interface between the lithium metal anode layer and the anode current collector is a lithium evaporation interface, and a second interface between the lithium metal anode layer and the separator or solid state electrolyte layer is a lithium evaporation interface. 
     
     
         9 . The lithium battery layer stack of  claim 7 , wherein the lithium metal anode layer comprises a lithium anode-first sublayer and a lithium anode-second sublayer directly contacting each other. 
     
     
         10 . The lithium battery layer stack of  claim 7 , wherein
 the cathode current collector is an Al foil or an Al coated polymer foil,   the cathode is an NMC cathode, and/or   the anode current collector is a copper foil or a copper coated polymer foil.