Aluminium foils for energy applications

Purpose and goal

Aluminium has very attractive properties for electrodes and current collectors in energy storage devices because, in addition to low weight and low cost, it offers excellent thermal and electrical conductivity as well as easy recyclability. However, the Al surface alone does not have the necessary performance. To achieve the desired properties, coating the Al with a thin layer of another material is necessary. This project aims at establishing production of coated Al foils with significantly improved surface properties.

Expected effects and result

The overall goal is to demonstrate a technical solution for production of coated Al foils for energy storage devices that meet industry requirements for applications. Their use in energy storage devices will reduce the weight and cost of such systems.

Planned approach and implementation

Physical vapour deposition will be used for coating of Al foils in a roll-to-roll geometry. As Al is ductile, the coating layer will be mechanically matched to the substrate material. In addition to the choice of the coating materials, the microstructure will be optimized in the deposition process. For a more rational materials development, the mechanical properties and adhesion of the coatings will be evaluated by tensile testing. The foils will be tested in collaboration with potential end users.