US 12,104,258 B2
Melt spinning methods for forming lithium-metal foils and electrodes of electrochemical devices
Michael P. Balogh, Novi, MI (US); Jin Liu, Novi, MI (US); Ryan C. Sekol, Grosse Pointe Woods, MI (US); Shaomao Xu, Sterling Heights, MI (US); and Erik D. Huemiller, Waterford, MI (US)
Assigned to GM Global Technology Operations LLC, Detroit, MI (US)
Filed by GM GLOBAL TECHNOLOGY OPERATIONS LLC, Detroit, MI (US)
Filed on Feb. 19, 2021, as Appl. No. 17/179,547.
Prior Publication US 2022/0267886 A1, Aug. 25, 2022
Int. Cl. B22D 11/06 (2006.01); C23C 6/00 (2006.01); H01M 4/04 (2006.01); H01M 4/38 (2006.01); H01M 4/66 (2006.01); H01M 10/0525 (2010.01); H01M 10/44 (2006.01); H01M 4/1395 (2010.01)
CPC C23C 6/00 (2013.01) [H01M 4/0404 (2013.01); H01M 4/0435 (2013.01); H01M 4/0485 (2013.01); H01M 4/382 (2013.01); H01M 4/667 (2013.01); H01M 10/0525 (2013.01); H01M 10/44 (2013.01); H01M 4/1395 (2013.01); H01M 2220/20 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of melt spinning lithium-metal foils, the method comprising:
melting a lithium (Li) metal stock in a vessel to form molten Li metal;
ejecting the molten Li metal through a slotted nozzle of the vessel;
cooling a carrier sheet fed across a support roller, the carrier sheet including a succession or sheet of solid-state electrode stackups carried on the carrier sheet, each of the solid-state electrode stackups including a metallic current collector;
applying the ejected molten Li metal onto the cooled carrier sheet fed across the support roller to form a sheet of molten Li metal; and
solidifying the sheet of molten Li metal on the cooled carrier sheet to form a Li-metal foil, wherein the molten Li metal solidifies and bonds to the solid-state electrode stackups via cooling of the carrier sheet.