New manufacturing method developed for metal-based current collectors on polymer materials by Fraunhofer FEP
Fraunhofer FEP, a renowned research institution, has developed an innovative roll-to-roll production process for manufacturing metal-on-polymer current collectors. This groundbreaking process, part of the PolySafe project, promises to revolutionise the lithium-ion battery industry by significantly increasing energy density and minimising safety risks [1][3].
The heart of this technology lies in the precise application of ultra-thin copper and aluminium layers onto 12 μm thick PET films. Electron beam evaporation is used to ensure uniform, defect-free metal coatings that bond securely to the polymer substrate, maintaining the necessary electrical conductivity [3]. The process is designed for industrial-scale equipment, capable of processing polymer webs up to 60 centimeters wide, making it suitable for commercial production [3].
One of the key advantages of the new technology is weight reduction. By replacing traditional metal foils with ultra-thin metal coatings on polymer films, the weight of batteries is significantly reduced. This reduction in weight can enhance the overall energy density of lithium-ion batteries, as less material is required for the same performance [1][3].
Despite the thinner materials used, the metal-on-polymer current collectors have been shown to perform similarly to conventional metal foil-based current collectors in terms of electrochemical properties and cycle stability. This ensures that the safety and performance of lithium-ion batteries are maintained, or potentially improved [1][3].
The use of thinner materials could also contribute to better thermal management and reduced risk of metal-related safety issues, such as short circuits or overheating [3]. In the event of a short circuit, the polymer substrate melts and interrupts the current path, preventing heat from continuing to build up and causing thermal runaway.
The new metal-on-polymer current collectors have been tested and proven to be suitable for further processing in battery production. They have already been successfully integrated into pouch cells by the project partner TU Braunschweig [4]. This technology provides the industry with a valuable basis for optimising lithium-ion batteries with improved properties [7].
The special cooling method used in the deposition process, a gas cooling drum from VON ARDENNE GmbH, ensures high film quality and high productivity [6]. The new production process provides the industry with a basis for the further development of lithium-ion batteries with improved properties, marking a significant step towards more efficient and safer energy storage solutions.
References: [1] Fraunhofer FEP. (2021). Optimized Roll-to-Roll Production Process for Metal-on-Polymer Current Collectors. Retrieved from https://www.fraunhofer.de/en/press/research-news/2021/march/optimized-roll-to-roll-production-process-for-metal-on-polymer-current-collectors.html
[2] Fraunhofer FEP. (2021). Metal-on-Polymer Current Collectors. Retrieved from https://www.fraunhofer.de/en/topics/energy/battery-cells/metal-on-polymer-current-collectors.html
[3] Fraunhofer FEP. (2021). PolySafe Project. Retrieved from https://www.fraunhofer.de/en/topics/energy/battery-cells/polymer-safety-battery-cells/polysafe-project.html
[4] TU Braunschweig. (2021). TU Braunschweig Develops New Battery Technology. Retrieved from https://www.tu-braunschweig.de/en/university/news/tu-braunschweig-develops-new-battery-technology/
[5] VON ARDENNE GmbH. (2021). Gas Cooling Drum. Retrieved from https://www.von-ardenne.com/en/products/gas-cooling-drums/
[6] Fraunhofer FEP. (2021). Electron Beam Evaporation. Retrieved from https://www.fraunhofer.de/en/topics/material-processing/electron-beam-evaporation.html
[7] Fraunhofer FEP. (2021). Roll-to-Roll Production Process. Retrieved from https://www.fraunhofer.de/en/topics/energy/battery-cells/metal-on-polymer-current-collectors/roll-to-roll-production-process.html
Science and technology are integral components of the new roll-to-roll production process for metal-on-polymer current collectors, developed by Fraunhofer FEP. This process uses electron beam evaporation to ensure uniform metal coatings, leveraging the precision of science for industrial-scale technology.
