Method for simultaneously forming alkali metal layers

A method for forming alkali metal layers, the method comprising:

• forming a first laminate structure by:
• positioning a facing surface of a top layer opposite a facing surface of a bottom layer, applying a volume of alkali metal between the facing surfaces of the top layer and the bottom layer;
• and
• simultaneously passing the top layer, the bottom layer, and the volume of alkali metal between a first set of rollers to transform the volume of alkali metal into a first alkali metal layer sandwiched between the facing surfaces of the top layer and the bottom layer;
• heating the first laminate structure to a peel temperature to at least partially melt the first alkali metal layer and form a volume of molten alkali metal at a first peel site disposed between the top layer and the bottom layer within the first alkali metal layer;
• and
• peeling the top layer and the bottom layer apart from each other such that the first alkali metal layer splits internally at the first peel site and is divided into a second alkali metal layer disposed on the top layer and a third alkali metal layer disposed on the bottom layer.

A method for forming alkali metal layers, the method comprising:

• (a) forming a first laminate structure by:
• positioning a facing surface of a top layer opposite a facing surface of a bottom layer, wherein a first alkali metal layer is disposed along the facing surface of the bottom layer, and wherein the facing surface of the top layer is substantially bare and does not include an overlying alkali metal layer;
• and
• simultaneously passing the top layer, the first alkali metal layer, and the bottom layer between a first set of rollers such that the first alkali metal layer is sandwiched between the facing surface of the top layer and the facing surface of the bottom layer;
• (b) heating the first laminate structure to a peel temperature to at least partially melt the first alkali metal layer and form a volume of molten alkali metal at a peel site between the top layer and the bottom layer within the first alkali metal layer;
• and
• (c) peeling the top layer and the bottom layer apart from each other such that the first alkali metal layer splits internally at the peel site and is divided into a second alkali metal layer disposed on the top layer and a third alkali metal layer disposed on the bottom layer,
• wherein the second alkali metal layer and the third alkali metal layer each have a thickness of greater than or equal to about 25% to less than or equal to about 75% of the thickness of the first alkali metal layer.