Lithium metal manufacturing using mask layer

Abstract

The present disclosure provides a patterned film for guiding lithium metal during lamination, including first and second regions having different thicknesses configured to direct selective placement, deformation, separation, and transfer of lithium metal onto substrates during roll pressing without mechanical slitting, punching, notching, or trimming. The patterned film may include concave configurations where thin regions form recessed cavities between thick regions, or convex configurations where thick regions form raised sections above thin regions. Methods involve positioning lithium metal adjacent to the patterned film, applying pressure through roll pressing to direct lithium according to the geometry defined by thick and thin regions, and transferring lithium onto substrates. Roll press-based fabrication systems include the patterned film, lithium metal feed layer, substrate, and roller units configured to apply selective pressure for lithium transfer according to the film pattern.

Dependencies are inferred from the claim text.