The commercial success of rechargeable lithium-related batteries in electronic devices since the 1990s has been remarkable. Technologies in the field continue to develop to make batteries safer, longer lasting, and more powerful. Emerging lithium-ion battery technologies such as solid-state batteries or high-silicon anode materials utilize, for example, ultra-thin lithium metal foil due to lithium metal high specific capacity (3860 mA h g-1), however; traditional thin lithium foil manufacturing methods have proven challenging at scale due to metal reactivity, poor foil tensile strength, and safety concerns. Additionally, lithium metal foil is needed in a variety of thicknesses, widths, and surface characteristics, which are all crucial for advancing lithium metal based batteries. Fortunately, it can be done via industry standard technologies when using LIOVIX®, Printable Lithium Technology.LIOVIX formulation has been coated using direct slot die technology at the benchtop scale and tension web slot die technology at the Roll-to-Roll (R2R) scale. Slot die technology facilitates two major elements of this process; particles larger than the theoretical wet film thickness can be deposited, and also the material can be shipped, delivered, and mixed without exposing lithium to air until it leaves the slot die head. This approach allowed us to achieve a uniform coating with heights ranging from 7 µm to 30 µm at a variety of coating widths. This has been done at the benchtop level at speeds up to 200 mm s-1 while maintaining a uniform coating on a copper substrate. R2R coating has done via a tension web coater, with similar theoretical wet film thickness. Specifically, the application of LIOVIX as a coating is particularly noteworthy for offering a strategic advantage in large scale manufacturing while maximizing the electrochemical performance.LIOVIX formulation enables the R2R production of lithium foil materials, and using a pre-metering system, the coating can be reliably produced at a variety of areal capacity targets.
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