Invention Reference Number
We developed and incorporated two innovative mPET/Cu and mPET/Al foils as current collectors in LIBs to enhance cell energy density under XFC conditions. These novel collectors facilitate a substantial reduction in weight (73%), thickness (33%), and cost (85%) relative 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. Under the XFC testing, higher mass loading of both the anodes and the cathodes leads to a decreased XFC capability. For anodes (3 to 4.8 mg/cm2), higher energy density was achieved at higher C-rate. As for cathode (6 to 9.5 mg/cm2), the highest XFC capability is achieved at 5C to 6.5C. In coin cell configurations, both RCRA and MCMA cells delivered comparable capacities under XFC, yet MCMA cells demonstrated a 27% energy density improvement at 6C (285 Wh/kg). Furthermore, in single-layer pouch cells, MCMA cells showed significant enhancements to energy density, with a 41% increase (337 Wh/kg) at 0.3C and a 32% increase (286 Wh/kg) at 6C under XFC conditions. Remarkably, even after 1000 cycles at 6C, the MCMA pouch cell maintained a respectable energy density of 120 Wh/kg at 22°C, underscoring its long-term performance viability. 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.
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