Vertically Integrated Pure Lithium Metal Production and Lithium Battery Production

A method of manufacturing a lithium electrode, comprising:

• (1) providing a gas-impermeable container, the container enclosing:
• a blanketing atmosphere, the blanketing atmosphere being substantially free of lithium reactive components;
• an electrolytic cell, the electrolytic cell being blanketed completely by the blanketing atmosphere, and including:
• a conductive substrate, stationary within the cell, configured as a negative electrode;
• a positive electrode;
• an aqueous lithium salt solution interposed between the conductive substrate and the positive electrode;
• a lithium ion-selective membrane configured to function as a solid state electrolyte, covering the conductive substrate, and forming a barrier separating the aqueous lithium salt solution and the conductive substrate;
• the electrolytic cell being configured to allow passage of lithium ions from the lithium salt solution through the lithium ion selective membrane and onto the surface of the conductive substrate, and to preclude the passage of other chemical species;
• (2) applying a variable voltage in order to maintain a constant current across the negative electrode and the positive electrode, thereby causing lithium ions to cross from the lithium salt solution through the lithium ion selective membrane, and electroplate a layer of lithium onto the conductive substrate, thereby forming the lithium electrode, the layer of lithium having an inner face and an outer face, the inner face bonding to the conductive substrate and the outer face bonding to the lithium ion-selective membrane;
• wherein the constant current is between about 10 mA/cm2 and about 50 mA/cm2, and wherein the constant current is applied for a time between about 1 minute and about 60 minutes.

A method of manufacturing a lithium electrode, comprising:

• (1) providing an electrolytic cell, the electrolytic cell including:
• a conductive substrate, stationary within the electrolytic cell, the conductive substrate comprising a plate having a first face and a second face;
• a first chamber containing a first positive electrode, and a first aqueous lithium salt solution in contact with the first positive electrode;
• a second chamber containing a first lithium ion-selective membrane separating the first chamber from the second chamber, and a first non-aqueous electrolyte disposed between the first face of the conductive substrate and the first lithium ion selective membrane, physically contacting both the first face of the conductive substrate and the first lithium ion selective membrane;
• a third chamber containing a second lithium ion-selective membrane and a non-aqueous electrolyte disposed between the second face of the conductive substrate and the second lithium ion selective membrane, physically contacting both the second face of the conductive substrate and the second lithium ion
• a fourth chamber containing a second positive electrode, and a second aqueous lithium salt solution in contact with the second positive electrode;
• the second lithium ion-selective membrane separating the third chamber from the fourth chamber;
• the electrolytic cell being configured to allow passage of lithium ions through the first lithium ion selective membrane between the first and the second chambers, and to preclude passage of other chemical species between the first and the second chambers;
• the electrolytic cell being configured to allow passage of lithium ions through the second lithium ion selective membrane between the fourth and the third chambers, and to preclude passage of other chemical species between the fourth and the third chambers;
• (2) blanketing completely the electrolytic cell with a blanketing atmosphere, the blanketing atmosphere being inert to chemical reaction with lithium;
• (3) applying a variable voltage in order to maintain a constant current across the conductive substrate and the first positive electrode, and across the conductive substrate and the second positive electrode, thereby causing lithium ions to cross from the first chamber to the second chamber, through the first lithium ion selective membrane and the first non-aqueous electrolyte, and electroplate a first layer of lithium onto the first face of the conductive substrate, and further causing lithium ions to cross from the fourth chamber to the third chamber, through the second lithium ion selective membrane and the second non-aqueous electrolyte, and electroplate a second layer of lithium onto the second face of the conductive substrate, thereby forming the lithium electrode, the lithium electrode comprising the conductive substrate, the first layer of lithium, and the second layer of lithium, the first layer of lithium having an inner face and an outer face, the inner face bonded to the first face of the conductive substrate, the second layer of having an inner face and an outer face, the inner face bonded to the second face of the conductive substrate;
• wherein the constant current is between about 10 mA/cm2 and about 50 mA/cm2, and wherein the constant current is applied for a time between about 1 minute and about 60 minutes.

A method of manufacturing a lithium electrode, comprising:

• (1) providing an electrolytic cell, the electrolytic cell including:
• a conductive substrate, stationary within the cell, the conductive substrate comprising a plate having a first face and a second face, the first face covered with a first lithium ion-selective membrane, and the second face covered with a second lithium ion-selective membrane, the first and second lithium ion-selective membranes configured to function as solid state electrolytes;
• a first chamber containing a first positive electrode, and a first aqueous lithium salt solution in contact with the first positive electrode and with the first lithium ion-selective membrane;
• a second chamber containing a second positive electrode, and a second aqueous lithium salt solution in contact with the first positive electrode and with the second lithium ion-selective membrane;
• the electrolytic cell being configured to allow passage of lithium ions through the first lithium ion selective membrane between the first chamber and the first face of the conductive substrate, and to preclude passage of other chemical species between the first chamber and the first face of the conductive substrate;
• the electrolytic cell being configured to allow passage of lithium ions through the second lithium ion selective membrane between the second chamber and the second face of the conductive substrate, and to preclude passage of other chemical species between the second chamber and the second face of the conductive substrate;
• (2) blanketing completely the electrolytic cell with a blanketing atmosphere, the blanketing atmosphere being inert to chemical reaction with lithium;
• (3) applying a variable voltage in order to maintain a constant current across the conductive substrate and the first positive electrode, and across the conductive substrate and the second positive electrode, thereby causing lithium ions to cross from the first chamber through the first lithium ion selective membrane, and electroplate a first layer of lithium onto the first face of the conductive substrate, and further causing lithium ions to cross from the second chamber through the second lithium ion selective membrane, and electroplate a second layer of lithium onto the second face of the conductive substrate, thereby forming the lithium electrode, the lithium electrode comprising the conductive substrate, the first layer of lithium, and the second layer of lithium, the first layer of lithium having an inner face and an outer face, the inner face of the first layer of lithium bonded to the first face of the conductive substrate, and the outer face of the first layer of lithium bonded to the first lithium ion-selective membrane, the second layer of lithium having an inner face and an outer face, the inner face of the second layer of lithium bonded to the second face of the conductive substrate, and the outer face of the second layer of lithium bonded to the second lithium ion-selective membrane;
• wherein the constant current is between about 10 mA/cm2 and about 50 mA/cm2, and wherein the constant current is applied for a time between about 1 minute and about 60 minutes.