Abstract: Methods are proposed for manufacturing dendrite-resistant lithium metal electrodes suitable for incorporation into lithium metal batteries. In an embodiment, the method involves first electroplating a copper sheet onto a surface of a single crystal of silicon, the silicon being doped to form a p-type or an n-type semiconductor, and then further electroplating the copper sheet with lithium metal. The lithium-electroplated copper sheet thus manufactured provides a lithium electrode that is resistant to dendrite formation during cycling of lithium metal batteries when compared to conventionally manufactured lithium electrodes. Methods are further provided of manufacturing lithium sheets by directly electroplating lithium metal onto single crystals of doped silicon, the lithium sheets configured for incorporation into lithium metal electrodes that are resistant to dendrite formation during cycling of lithium metal batteries.

Abstract: Methods are proposed for fabricating highly pure lithium metal electrodes from aqueous lithium salt solutions. Electrolysis is performed through lithium ion selective membranes, with constant current densities between about 10 mA/cm2 and about 50 mA/cm2 being applied for a time between about 1 minute and about 60 minutes. The electrolysis is performed under a blanketing atmosphere, the blanketing atmosphere being substantially free of lithium reactive components. Methods are further proposed for vertically integrating the electrolytic fabrication of highly pure lithium metal electrodes into the production of lithium metal batteries, the fabrication of lithium electrodes and lithium metal batteries being performed in a single facility.

Abstract: A lithium metal electrode has no more than five ppm of non-metallic elements by mass, and is bonded to a conductive substrate. Optionally, the lithium metal electrode may be bonded on one side to a conductive substrate and on another side to a lithium ion selective membrane. The lithium metal electrode may be integrated into lithium metal batteries. The inventive lithium metal electrode may be manufactured by a process involving electrolysis of lithium ions from an aqueous lithium salt solution through an ion selective membrane, carried out under a blanketing atmosphere having no more than 10 ppm of non-metallic elements, the electrolysis being performed at a constant current 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.