The breakthrough at the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) could reconstruct the future of electric vehicles (EVs).
ORNL scientists have announced a new type of current collector that can significantly speed up EV charging times, increase energy density and reduce reliance on important raw materials such as copper.
This breakthrough could play a pivotal role in changing the competitiveness of the US transport sector.
Why fast EV charging is important
Improved EV charging times is not just a convenience, but a strategic need. For the US to remain competitive in the global automotive market, it is essential to develop domestically produced EV batteries that can be quickly recharged and support long-distance driving.
However, high energy density – a critical requirement for long travel – can usually impose charging speed and battery life. Filling this gap is important for large-scale EV adoption and manufacturing leadership.
New current collector technology offers a way to overcome this trade-off, offering both high energy density and the ability to handle very fast charging, recovering 80% of battery energy in just 10 minutes.
This could eliminate one of the biggest hurdles facing today’s EV infrastructure.
What is the current collector?
The current collector is the foundational component of all lithium-ion batteries. It conducts current from the active material of the battery to the external circuit.
Typically these are made of copper (for the anode) and aluminum (for the cathode) which adds a considerable amount of weight and cost to the battery pack.
Heavy batteries reduce vehicle efficiency and increase energy consumption, while the increasing global demand for copper and aluminum creates supply chain vulnerability. ORNL innovation addresses both issues.
Lighter, cheaper, more efficient current collector
In a partnership with the Soteria Battery Innovation Group, ORNL researchers have developed a new metallized polymer current collector.
It consists of a thin polymer core layered with ultra-thin copper or aluminum. This design reduces metal usage by up to 85%, reduces collector weight by 75%, provides 27% energy per charge, allowing longer trips on a single charge.
Additionally, the new collectors retain their performance even after 1,000 extreme high-speed charge cycles, a scenario in which traditional batteries often deteriorate rapidly. Results: Decreased battery life length, charging speed, and the need for critical raw materials.
Compatibility with mass production
A common barrier to battery innovation is scalability. Many alternatives to today’s traditional collectors require complex manufacturing methods that are incompatible with industry-standard roll-to-roll production. Ornl took this challenge head on.
Researchers have integrated a new lightweight collector into coin cells and pouch cells using the same roll-to-roll method found in commercial battery plants.
Despite the tendency to wrinkle in thin materials, the team has identified the optimal processing parameters that can be viable for mass production. This paves the way for commercial adoption without the need for major infrastructure overhauls.
Smart design increases safety
In addition to performance and cost benefits, metallized polymer current collectors increase battery safety.
If a short circuit occurs, the plastic components of the collector will melt, separate the metal layer, disrupt current flow, and function effectively like a built-in circuit breaker. According to Soteria testing, this design reduces the risk of lithium-ion battery fires by up to 90%.
Accelerating the US’s EV transition
Funded by DOE’s Advanced Materials and Manufacturing Technologies Office (AMMTO), this innovation represents a critical step towards more sustainable, high-performance EV batteries.
By reducing dependence on imported metals and improving fast charging capabilities, it perfectly aligns with the national goals of energy security and industrial competitiveness.
As the EV market accelerates, technology like this new, current collector-like can define the next generation of American-made electric vehicles.
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