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At least 19 records

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DOE OSTI2025

Metalized Polymer Current Collector for High-Energy Lithium-Ion Batteries with Extreme Fast-Charging Capability

Electric vehicles are pivotal in the global shift toward decarbonizing road transport, with lithium-ion batteries at the heart of this technological evolution. However, the pursuit of batteries capable of extremely fast charging that also satisfy high energy and safety criteria, poses a significant challenge to current lithium-ion batteries technologies. Additionally, the increasing demand for aluminum (Al) and copper (Cu) in electrification, solar energy technologies, and vehicle light-eighting is driving these metals toward near-critical status in the medium term. This study introduces metalized polythylene terephthalate (mPET) polymer films by depositing an Al or Cu thin layer onto two sides of a polyethylene terephthalate film—named mPET/Al and mPET/Cu, as lightweight, cost-effective alternatives to traditional metal current collectors in lithium-ion batteries. We have fabricated current collectors that significantly reduce weight (by 73%), thickness (by 33%), and cost (by 85%) compared with traditional metal foil counterparts. These advancements have the potential to enhance energy density to 280 Wh kg -1 at the electrode level under 10-min charging at 6 C. Through testing, including a novel extremely fast charging protocol across various C-rates and long-term cycling (up to 1000 cycles) in different cell configurations, the superior performance of these metalized polymer films has been demonstrated. Notably, mPET/Cu and mPET/Al films exhibited comparable capacities to conventional cells under extremely fast charging, with the mPET cells showing a 27% improvement in energy density at 6 C and maintaining significant energy density after 1000 cycles. This study underscores the potential of mPET films to revolutionize the roll-to-roll battery manufacturing process and significantly advance the performance metrics of lithium-ion batteries in electric vehicles applications.

25 ENERGY STORAGE↗

DOE OSTI2025

Multilayer Electrodes with Metalized Polymer Current Collector for High-Energy Lithium-Ion Batteries with Extreme-Fast-Charging Capability

The pursuit of batteries capable of extreme fast charging (XFC), that also satisfy high energy and safety criteria, poses a significant challenge to current lithium-ion battery technologies. Additionally, the increasing demand for aluminum (Al) and copper (Cu) in electrification, and vehicle light weighting is driving these metals towards near-critical status in the medium term. This study introduced metalized polymer films by depositing an Al or Cu thin layer onto two sides of a polyethylene terephthalate (PET) film – named mPET/Al and mPET/Cu, as lightweight, cost-effective alternatives to traditional metal current collectors in LIBs. We have utilized current collectors that significantly reduce weight (by 73%), thickness (by 33%), and cost (by 85%) compared to traditional metal foil counterparts. We conducted an extensive evaluation of their mechanical and electrical properties, including in-plane and through-plane resistivities, affirming their suitability for the roll-to-roll battery manufacturing process. Additionally, a novel XFC testing protocol was employed to thoroughly assess the cells' (both half and full-cell) performance across various C-rates and under long-term tests. These advancements have the potential to enhance energy density to 280 Wh/kg at the electrode level under 10-minute charging at 6C. Through testing, including a novel XFC protocol across various C-rates and long-term cycling (up to 1000 cycles) in different cell configurations, we have demonstrated the superior performance of these metalized polymer films. Notably, mPET/Cu and mPET/Al foils exhibited comparable capacities to conventional cells under XFC, with the mPET cells showing a 27% improvement in energy density at 6C and maintaining significant energy density after 1000 cycles. This study underscored the potential of mPET foils to revolutionize the roll-to-roll battery manufacturing process and significantly advance the performance metrics of LIBs in EV applications. Moreover, our results suggest that there is potential to enhance the performance of mPET foils, especially mPET/Al, by optimizing the manufacturing process to achieve higher conductivity.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Multilayer Electrodes with Metalized Polymer Current Collector for High-Energy Lithium-Ion Batteries with Extreme-Fast-Charging Capability

25 ENERGY STORAGE↗

DOE OSTI2021

Prevention of lithium-ion battery thermal runaway using polymer-substrate current collectors

Isolating electronically conducting material from internal short circuits is a promising way to prevent the onset of thermal runaway within lithium-ion cells. Here, a metal-coated polymer current collector, which is designed to disconnect internal short circuits by withdrawing from the heating region, is tested in 18650 cells. In addition to having lower mass and manufacturing costs, cells with metal-coated polymer current collectors demonstrate a reduced risk of thermal runaway during nail penetration. High-speed synchrotron X-ray radiography of 18650 cells during nail-penetration testing, in tandem with pre- and post-mortem X-ray computed tomography, provides insights into the function of the current collectors. The results are compared with those of 18650 cells with standard commercial aluminum and copper current collectors. Cells with aluminum-coated polymer current collectors demonstrated 100% success in thermal runaway prevention during nail penetration, retaining a cell voltage >4.00 V, while standard cells consistently experienced thermal runaway.

25 ENERGY STORAGE↗

DOE OSTI2022

Cold-Starting All-Solid-State Batteries from Room Temperature by Thermally Modulated Current Collector in Sub-Minute

All-solid-state batteries (ASSBs) show great potential as high-energy and high-power energy storage devices but their attainable energy/power density at room temperature is severely reduced because of the sluggish kinetics of lithium-ion transport. Here we first reported a thermally modulated current collector (TMCC), which can rapidly cold-start ASSBs from room temperature to operating temperatures (70–90 °C) in less than one minute, and simultaneously enhance the transient peak power density by 15-fold compared to one without heating. This TMCC is prepared by integrating a uniform, ultrathin (~200 nm) nickel layer as a thermal modulator within an ultralight polymer-based current collector. By isolating the thermal modulator from the ion/electron pathway of ASSBs, it can provide fast, stable heat control yet does not interfere with regular battery operation. Moreover, this ultrathin (13.2 μm) TMCC effectively shortens the heat transfer pathway, minimizes heat losses, and mitigates the formation of local hot spots. The simulated heating energy consumption can be as low as ~3.94% of total battery energy. This TMCC design with good tunability opens new frontiers towards smart energy storage devices in the future from the current collector perspective.

25 ENERGY STORAGE↗

DOE OSTI2022

Lithium-Ion Batteries with Safer Current Collectors

The US Department of Energy’s Oak Ridge National Laboratory and Soteria Battery Innovation Group collaborated to develop a metallized polymer film as a current collector for lithium-ion batteries and design slit patterns for electrodes to improve battery safety. The metallized polymer film serves as a fuse that will break under high temperature resulting from a short circuit. Consequently, the short circuit will be broken and the heat generated from the short circuit will be alleviated to avoid thermal runaway. The electrodes with slit patterns are expected to be broken into small segments upon mechanical impact, which can isolate the damaged electrodes from the rest. Thus, the heat generation associated with the mechanical impact will be reduced, along with the likelihood of thermal runaway. This effort aimed to improve lithium-ion battery safety by replacing traditional metal foils with metallized polymer films as current collector and introducing slit patterns to battery electrodes. The metallized polymer films were polyethylene terephthalate with a thin metal (aluminum for cathodes and copper for anodes) coating on both sides. Slit patterns with various geometries and dimensions were designed via simulation. Temperature distribution on cells with electrodes with and without slit patterns was also simulated via nemerical modeling. Electrodes on traditional metal foils and metallized polymer films were coated via a pilot-scale slot-die coater at the US Department of Energy Battery Manufacturing Facility at Oak Ridge National Laboratory. The electrodes were calendered to 35% porosity and punched out with and without slit patterns. Pouch cells were assembed with the electrodes inside a dry room for electrochemical and safety testing. Electrodes coated on metallized polymer films exhibited comparable electrochemical performance to their counterparts coated on traditional metal foils. They also showed improved safety in nail penetration and indentation tests.

25 ENERGY STORAGE↗

DOE OSTI2023

Aligned carbon fibers-carbon nanotube-polymer-based composite as lithium-ion battery current collector

High energy density demand is pushing the development of high-voltage cathode materials, which necessitates improved electrochemical stability of other battery components such as binders, electrolytes, and current collectors. Current collectors are considered to be an inactive component but still play an essential role. In this study, a metal-free composite film containing directionally aligned carbon fiber (CF), carbon nanotube (CNT), and polymer (P) was developed to replace aluminum foil as a cathode current collector, which relies on forming an Al 2 O 3 layer to ensure electrochemical stability at high voltage. Here, each component in the new cathode current collector played a functional role. The CNTs provided uniform current densities, and CFs improved the electronic conductivity and mechanical strength of the composite material. The polymer enhanced the adhesion of the cathode coating with the current collector and provided an impervious support to the cathode materials. The CF-CNT-P composite demonstrated excellent electrochemical and thermal stability. Cathodes coated on the CF-CNT-P composite exhibited lower charge transfer resistance, improved rate capability, and improved cyclic stability compared with the cathodes deposited on conventional aluminum foil. Additionally, the composite current collector was lighter (1.81 mg/cm 2 and 15 µm thick) than the commonly used aluminum foil (4.35 mg/cm2 and 15 µm thick), which can increase the cell energy density. Additionally, the CF-CNT-P did not need to be separated from the cathode coating during recycling and can be burnt out with binder, simplifying the recycling process.

25 ENERGY STORAGE↗

DOE OSTI2021

Actinic and electron beam radiation curable water based electrode binders and electrodes incorporating same

A process for manufacturing an electrode utilizing electron beam (EB) or actinic radiation to cure the electrode binder is provided. A process is also disclosed for mixing specific actinic or EB radiation curable polymer precursors with electrode solid particles to form an aqueous mixture, application of the mixture to an electrode current collector, followed by the application of actinic or EB radiation to the current collector for curing the polymer, thereby binding the electrode binder to the current collector. Lithium ion batteries, electric double layer capacitors, and components produced therefrom are also provided.

Voelker, Gary E.↗

DOE OSTI2022

Polymer-Stabilized Liquid Metal Nanoparticles as a Scalable Current Collector Engineering Approach Enabling Lithium Metal Anodes

Dendrites and dead lithium formation over prolonged cycling have long been challenges that hinder the safe implementation of metallic Li anodes. In this study, we employ polymer-stabilized liquid metal nanoparticles (LM-P NPs) of eutectic gallium indium (EGaIn) to create uniform Li nucleation sites enabling homogeneous lithium electrodeposition. Block copolymers of poly(ethylene oxide) and poly(acrylic acid) (PEO-b-PAA) were grafted onto the EGaIn surface, forming stabilized, well-dispersed NPs. Using a scalable spray coating approach, LM-P NPs were fabricated on copper current collectors, providing lithiophilic PEO sites and interactive carboxyl groups to guide Li deposition. The Li-EGaIn alloying process greatly reduced the Li + diffusion barrier, enabling fast Li transport through the coating layer, resulting in decreased nucleation overpotential. Therefore, about five times lower Li nucleation overpotential was obtained on the LM-P modified Cu with an optimal composition of the polymers than the bare Cu substrates. DFT computations was used to reveal the binding properties between the LM-P layer and Li. Due to the regulated Li plating/stripping process, as-obtained 30 μm Li anodes paired with LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NCM8 11 ) with a negative/positive electrode capacity (N/P) ratio ~ 10 exhibited stable cycling performance at 0.5C for over 250 cycles, with an average Coulombic efficiency of 99.55%. Ultrathin Li (1 μm) anodes with an N/P ratio ~ 0.6 were also demonstrated in Li|LiFePO 4 cells, which examined the stabilization of Li by LM-P NPs and monitored practical loadings of Li anodes that are close to anode-free systems.

25 ENERGY STORAGE↗

DOE OSTI2022

Large-format battery anodes comprising silicon particles

Large-scale anodes containing high weight percentages of silicon suitable for use in lithium-ion energy storage devices and batteries, and methods of manufacturing the same, are described. The anode material described herein can include a film cast on a current collector substrate, with the film including a plurality of active material particles and a conductive polymer membrane coated over the active material particles. In some embodiments, the conductive polymer membrane comprises polyacrylonitrile (PAN). The method of manufacturing the anode material can include preparation of a slurry including the active material particles and the conductive polymer material, casting the slurry on a current collector substrate, and subjecting the composite material to drying and heat treatments.

25 ENERGY STORAGE↗

DOE OSTI2024

Large-format battery anodes comprising silicon particles

Evans, Tyler↗

DOE OSTI2023

A lightweight and metal-free current collector for battery anode applications

The requirement for high energy density batteries is driving the development of high-capacity electrode materials while reducing the amount of inactive battery components such as separators, binders, and current collectors. Though current collectors are an inactive component, they are still required for successful working of a battery cell. Conventional current collectors include aluminum foil for cathode and copper foil for anode. Copper foil is quite heavy (8.7 mg/cm 2 ) for 10μm thickness. Therefore, there is a need for a lightweight current collector for anode applications. In this work, a metal-free current collector comprised of aligned carbon fiber (CFs) layer filled with carbon nanotubes (CNTs) mixed in polymer (P) is developed to be used as a current collector for anodes. Further, anodes coated on the CF-CNT-P showed lower charge transfer resistance and improved rate capability compared with the anodes fabricated on conventional copper foil-based current collectors. The CF-CNT-P are lighter (≈1.5 mg/cm 2 ) than the commonly used copper foil (8.7 mg/cm 2 ), which will increase the gravimetric energy density.

25 ENERGY STORAGE↗

DOE OSTI2025

The Effect of a Carbon Fiber Layer Between the Cathode and the Current Collector on Battery Cell Performance

Contact resistance between the cathode active material (CAM) and the Al current collector can be reduced by applying carbon coatings to the Al current collector surface. However, this process requires an additional step of carbon layer coating on the current collector, which increases both manufacturing costs and processing time. In the present work, an interlayer of continuous unsized carbon fibers aligned in one direction (CF interlayer), is introduced between the Al current collector and the NMC811 cathode during cathode deposition on the Al current collector. This single-step approach eliminates the need for the additional carbon layer coating on the current collector. Additionally, this approach removes the use of toxic solvents and insulative polymers used for making the carbon coating. The CF interlayer improves the rate capability at higher C-rates. The CF interlayer lowers the contact resistance between the cathode particles and the current collector while improving the activation energy of charge transfer. The peel test showed that the CF interlayer does not affect the adhesion strength of the cathode layer with the current collector.

25 ENERGY STORAGE↗

DOE OSTI2020

Sustainable Direct Recycling of Lithium-Ion Batteries via Solvent Recovery of Electrode Materials

Separation of electrode materials from their current collectors is an enabling step toward recovering critical materials from spent lithium-ion batteries. In this study, a highly efficient, cost-effective, and environmentally sustainable separation process was developed for that purpose. Ethylene glycol, a vital commodity chemical as an antifreeze and polymer precursor, is used to delaminate electrode materials at low temperatures in seconds without altering the crystalline structure and morphology of active electrode materials. The recovered current collectors were intact without any corrosion. The authors also found that the solvent could be continuously reused, leading to the development of a closed-loop ecosystem and lithium-ion battery circular economy. The ultrafast delamination was driven by the competitive inhibition of binding through the weakening of hydrogen bonding. The ethylene glycol-based separation is a sustainable electrode recovery process that paves the way for battery recycling.

25 ENERGY STORAGE↗

DOE OSTI2024

Assessment of the polygeneration approach in wastewater treatment plants for enhanced energy efficiency and green hydrogen/ammonia production

Wastewater treatment plants (WWTPs) offer opportunities to optimize resource utilization and enhance energy efficiency. Here, this study provides a comprehensive analysis of using the polygeneration approach in WWTPs to reduce grid energy dependence, optimize energy distribution, and utilize surplus energy for hydrogen (H 2 ) and ammonia (NH 3 ) production. Several models were employed, including photovoltaic (PV) cells, parabolic trough collectors (PTCs), steam methane reforming, and polymer electrolyte membranes, to assess the feasibility of this approach. Three scenarios were evaluated and compared: Scenario 1 (Baseline) represents the current situation, Scenario 2 maximizes the Net Present Value (NPV), and Scenario 3 minimizes NH 3 production costs. Real data from As-Samra WWTP in Jordan was used to accurately assess the feasibility of each scenario. The results show that Scenario 2 offers the highest profitability and efficiency, with a NPV of 87.48 million USD and an annual NH 3 production of 15,417 tons, reducing both grid dependency and biogas fuel consumption. Both Scenarios 2 and 3 demonstrate the ability to meet thermal demands efficiently while generating significant revenue from NH 3 production. Scenario 3, in particular, achieves competitive H 2 and NH 3 production costs. Environmentally, Scenario 2 significantly reduces annual greenhouse gas emissions by 12.66 kilotons of CO 2eq , with near-zero carbon intensity for thermal energy due to solar reliance. In conclusion, the polygeneration approach offers a promising pathway for WWTPs to achieve greater sustainability, economic gains, and reduced environmental impact, providing valuable insights for decision-makers.

42 ENGINEERING↗

DOE OSTI2024

Electrospinner Upgrades for Nanofiber Production

Electrospinning is an inexpensive and flexible method for producing nanofibers. Nanofibers are highly adaptable with potential applications in accelerator target systems, air and water filtration, and biomedicine. This project aims to upgrade and test an existing roll-to-roll electrospinner that is more economical for industrial nanofiber production. Varying the diameter of nanofiber can change its functional properties. The current unit cannot adjust spinneret-collector separation, which determines nanofiber diameter. The electro-spinneret channel also does not have lateral adjustment capabilities for precise alignment. Lastly, the viscosities of our polymer solutions have not been quantified. Solution injection into the channel is presently inconsistent because of imperfect nozzle sizing, resulting in waste and decreased efficiency. Modeling was done with Siemens NX CAD software, and viscosity was measured using a Brookfield DVE-LV viscometer. A dual scissor lift design for channel displacement, powered by a dual-shaft DC motor coupled to precision lead screws, was approved and construction was started. Preliminary channel modifications also were initiated. Going forward, the scissor lift system will be integrated and evaluated with our electrospinner, along with further channel modifications. Viscosity measurements of polyvinyldimethylformamide (PVDF) were recorded with inconsistent results due to inadequate testing conditions. Future viscosity trials must be completed in accordance with testing requirements. The optimization and commercialization of roll-to-roll electrospinner units can make nanofiber production more feasible for many new industries and consumer products.

Black, Niko↗

DOE OSTI2024

Electroanalytical Exploration of Li Loss at the Solid Electrolyte-Anode Interface in Anode-Free Batteries with Polymer Electrolytes

Li loss during cycling at the solid electrolyte|anode interface strongly determines the cycle life of anode-free solid-state batteries (SSBs). Here, this loss is probed electroanalytically for polymer electrolyte (PE)-based SSBs in anode-free coin cells with practical pressures. A wide range of parameters expected to impact the measured average coulombic efficiency (CE) were explored to estimate the expected range of performance. These factors include PE type, cycling profiles, current collector type, and the presence of a thin Li seed layer. Further, low CE values in the ~50%–85% range are observed for all electrolytes and test conditions. Other than the electrolyte type, a strong dependence of the CE on the electrochemical cycling profile and the type of metallic current collector is observed. Compared to the anode-free setup, the presence of a thin (5 μ m) Li seed layer did not improve the average CE for two out of three PEs, suggesting its presence to be a weak contributor in minimizing the Li loss. This work provides baseline data on the Li losses in low-pressure anode-free configuration cells with PEs.

25 ENERGY STORAGE↗

DOE OSTI2025

Long carbon fibers boost performance of dry processed Li-ion battery electrodes

Dry processing (DP) is an advanced manufacturing technique for lithium-ion battery (LIB) electrodes. Unlike conventional wet-process-based manufacturing that involves dissolving polyvinylidene fluoride (PVDF) binder in n-methyl-2-pyrrolidone (NMP) solvent for slurry-casting, DP involves fibrillation of polymer binders. This method offers environmental and cost benefits by eliminating the need for expensive and environmentally hazardous organic solvents. However, DP-produced electrode films often lack mechanical stability due to the absence of a current collector substrate during electrode material layer fabrication. This reduced mechanical instability results in difficulty during fabricating of thin electrodes (≈5 mAh/cm 2 ). To address this issue, long (>8 mm) carbon fiber (CF) has been incorporated to reinforce the mechanical strength of the electrode films. In conclusion, the study demonstrates that the inclusion of long carbon fiber boosts the mechanical, electrical, thermal, and electrochemical performance of DP electrodes.

25 ENERGY STORAGE↗