# US 2025/0158013 A1 · One-sided rolling insertion of thick lithium into a 3d current collector

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- Number: US 2025/0158013 A1
- Document ID: US20250158013A1
- Status: Published application
- Kind: A1
- Application number: 18/507,783
- Filed: 2023-11-13
- Published: 2025-05-15
- Earliest claimed: 2023-11-13
- Assignees: GM Global Technology Operations LLC
- Applicants: GM Global Technology Operations LLC
- Inventors: Joel G. TONER; Diptak BHATTACHARYA; Caleb REESE; Andrew Clay BOBEL; Anil K. SACHDEV
- Web page: https://patentgrep.com/patent/US20250158013A1

## CPC

- H01M 4/0435: {Rolling or calendering}
- H01M 4/382: {Lithium (H01M4/405 takes precedence)}
- H01M 10/052: Li-accumulators
- H01M 2004/027: {Negative electrodes}
- Y02E 60/10: Energy storage using batteries
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A method for manufacturing an electrode for a battery cells includes supplying an active material layer, a current collector, and a dummy current collector between a first roller and a second roller; using one of the first roller and the second roller, biasing the current collector into the active material layer below an outer surface of the active material layer using the dummy current collector; and removing the dummy current collector from the active material layer.

## Claims

### Claim 1

A method for manufacturing an electrode for a battery cells, comprising:
supplying an active material layer, a current collector, and a dummy current collector between a first roller and a second roller;
using one of the first roller and the second roller, biasing the current collector into the active material layer below an outer surface of the active material layer using the dummy current collector; and
removing the dummy current collector from the active material layer.

### Claim 2 (depends on 1)

The method of claim 1, wherein the electrode comprises an anode electrode and the active material layer comprises a lithium layer.

### Claim 3 (depends on 2)

The method of claim 2, wherein the lithium layer has a thickness greater than 60 μm.

### Claim 4 (depends on 1)

The method of claim 1, wherein the current collector comprises an anode current collector.

### Claim 5 (depends on 2)

The method of claim 2, wherein the current collector comprises a three dimensional current collector.

### Claim 6 (depends on 5)

The method of claim 5, wherein the current collector comprises a metal mesh.

### Claim 7 (depends on 1)

The method of claim 1, wherein the current collector and the dummy current collector have the same pitch and pattern.

### Claim 8 (depends on 1)

The method of claim 1, further comprising, after removing the dummy current collector, rolling the active material layer one or more times to enclose the current collector in the active material layer.

### Claim 9 (depends on 1)

The method of claim 1, wherein the dummy current collector comprises a substrate and a pattern of raised portions arranged on the substrate.

### Claim 10 (depends on 9)

The method of claim 9, wherein the pattern of raised portions aligns with a pattern of wires of the current collector.

### Claim 11 (depends on 9)

The method of claim 9, wherein the dummy current collector comprises a continuous layer.

### Claim 12

A method for manufacturing an electrode for a battery cells, comprising:
supplying an active material layer and a current collector between a first roller and a second roller,
wherein the first roller includes a pattern of raised portions corresponding to a pattern of wires of the current collector; and
using the pattern of raised portions of the first roller to bias the current collector into the active material layer below an outer surface of the active material layer.

### Claim 13 (depends on 12)

The method of claim 12, wherein the electrode comprises an anode electrode and the active material layer comprises a lithium layer.

### Claim 14 (depends on 13)

The method of claim 13, wherein the lithium layer has a thickness greater than 60 um.

### Claim 15 (depends on 12)

The method of claim 12, wherein the current collector comprises an anode current collector.

### Claim 16 (depends on 11)

The method of claim 11, wherein the current collector comprises a three dimensional current collector.

### Claim 17 (depends on 16)

The method of claim 16, wherein the current collector comprises a metal mesh.

### Claim 18 (depends on 11)

The method of claim 11, wherein wires of the current collector and the pattern of raised portions have the same pitch and pattern.

### Claim 19 (depends on 12)

The method of claim 12, further comprising rolling the active material layer one or more times to enclose the current collector in the active material layer.