batteries are currently the most powerful energy storage technology, particularly for powering mobile electronic devices and electric vehicles. [1][2][3] Improved Li-ion batteries and alternatives, such as Li-metal batteries, [4] Li-S batteries, [5] and solid-state batteries, [6] have the potential to effectively address current civilization challenges such as global warming, environmental pollution, and depletion of fossil fuel resources, paving the way to a sustainable future. To this end, academia and industry around the world are conducting intensive research into various ways to improve existing batteries or bring novel concepts into application. The development of advanced materials and electrodes is one of the most important steps in this process. [7][8][9][10] On a daily basis, reports of improved active materials or electrode architectures that significantly outperform established batteries are published in the scientific literature. However, the transfer of these innovations into practical application is rather rare. This may be due to difficulties in scaling the corresponding production routes to an industrially relevant level. Another possible reason is that promising performance metrics at the material level are not achieved in practical batteries, due to the different definition of performance parameters at the different technological levels, i.e., material, electrode, cell, system, etc.Various renowned scientists have already addressed these shortcomings in the presentation of performance data of new battery materials and electrodes in scientific literature [6,[11][12][13][14][15] and explicitly alert that extraordinary power claims for components used in batteries often do not hold up at the device level. These authors emphasize that reporting energy and power densities per weight of active material or electrode alone does not provide a realistic picture of the performance that an assembled device could achieve because it does not consider the weight of other necessary components. For example, it is well known that the rate capability scales with the electrode thickness. [16][17][18] Very thin electrodes (<20 µm) can be charged in a few minutes whereas thick electrodes (>100 µm) need several hours to achieve full capacity. When considering the specific capacity obtained at high rates in terms of mAh g -1 with respect to the mass of active material, the thin electrodes clearly outperform the thick ones. However, considering the power density Large-scale electrochemical energy storage is considered one of the crucial steps toward a sustainable energy economy. Science and industry worldwide are conducting intensive research into various ways to improve existing battery concepts or transferring novel concepts to application. The development of materials and electrodes is an essential step in this process. However, the evaluation of the achieved performance parameters and the comparison of the different studies at this technological level with regard to practical applications is challenging, since spec...
A hermetic dense polymer-carbon composite-based current collector foil (PCCF) for lithium-ion battery applications was developed and evaluated in comparison to state-of-the-art aluminum (Al) foil collector. Water-processed LiNi0.5Mn1.5O4 (LMNO) cathode and Li4Ti5O12 (LTO) anode coatings with the integration of a thin carbon primer at the interface to the collector were prepared. Despite the fact that the laboratory manufactured PCCF shows a much higher film thickness of 55 µm compared to Al foil of 19 µm, the electrode resistance was measured to be by a factor of 5 lower compared to the Al collector, which was attributed to the low contact resistance between PCCF, carbon primer and electrode microstructure. The PCCF-C-primer collector shows a sufficient voltage stability up to 5 V vs. Li/Li+ and a negligible Li-intercalation loss into the carbon primer. Electrochemical cell tests demonstrate the applicability of the developed PCCF for LMNO and LTO electrodes, with no disadvantage compared to state-of-the-art Al collector. Due to a 50% lower material density, the lightweight and hermetic dense PCCF polymer collector offers the possibility to significantly decrease the mass loading of the collector in battery cells, which can be of special interest for bipolar battery architectures.
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