New Roll-to-Roll Production Process for Metal-Polymer Collectors Developed

According to foreign media reports, the Fraunhofer Institute for Electron Beam and Plasma Technology (Fraunhofer FEP) has developed a novel roll-to-roll production process for manufacturing metal-polymer collectors. This technology enables the precise coating of copper and aluminum layers on polymer films, producing collectors with conductivity and thickness comparable to traditional metal foil collectors. These advancements provide valuable insights for the industry to optimize lithium-ion batteries. It's hard to imagine a modern world without lithium-ion batteries, as they power mobile devices like smartphones, tablets, robotic vacuum cleaners, and electric vehicles. However, their many advantages, such as high energy density, compact design, and long lifespan, are overshadowed by a significant drawback: the risk of fire due to lithium's characteristics (highly flammable and reactive). Overcharging, damage, or overheating can lead to uncontrolled energy release, known as thermal runaway. The developed process allows for the replacement of traditional collectors (typically metal foils) with metal-polymer collectors. These collectors consist of polymer foils coated with thin layers of aluminum or copper on both sides. They offer numerous benefits: they reduce the weight of the collector, thereby increasing the energy density of the battery. More importantly, they enhance safety: if a battery cell experiences a short circuit, the polymer substrate melts and interrupts the current path, preventing heat from accumulating and leading to thermal runaway.