In collaboration with Wuhan University of Technology and Shenzhen University, researchers at Swansea University have developed a scalable method for producing large graphene current collectors, which significantly enhances the safety and performance of lithium-ion batteries (LIBs). This innovative approach addresses a critical challenge in energy storage technology.
Published in Nature Chemical Engineering, the study outlines the first successful protocol for fabricating defect-free graphene foils on a commercial scale. These foils exhibit remarkable thermal conductivity—up to 1,400.8 W m–1 K–1—nearly ten times greater than traditional copper and aluminum current collectors used in LIBs.
Dr. Rui Tan, co-lead author from Swansea University, stated, “This is a significant step forward for battery technology. Our method allows for the production of graphene current collectors at a scale and quality that can be readily integrated into commercial battery manufacturing. This not only improves battery safety by efficiently managing heat but also enhances energy density and longevity.”
Addressing the issue of thermal runaway in LIBs is crucial, especially for high-energy applications like electric vehicles. Thermal runaway occurs when excessive heat leads to battery failure, often resulting in fires or explosions. The newly developed graphene current collectors are designed to mitigate this risk by efficiently dissipating heat and preventing the exothermic reactions that can lead to thermal runaway.
Dr. Jinlong Yang, co-lead author from Shenzhen University, elaborated, “Our dense, aligned graphene structure provides a robust barrier against the formation of flammable gases and prevents oxygen from permeating the battery cells, which is crucial for avoiding catastrophic failures.”
The new process is not only a laboratory success but also a scalable solution capable of producing graphene foils in lengths ranging from meters to kilometers. In a notable demonstration, the researchers created a 200-meter-long graphene foil with a thickness of 17 micrometers. This foil maintained high electrical conductivity even after being bent over 100,000 times, making it suitable for flexible electronics and other advanced applications.
Additionally, this approach allows for the production of graphene foils with customizable thicknesses, potentially leading to even more efficient and safer batteries.
This innovation has significant implications for the future of energy storage, particularly in electric vehicles and renewable energy systems, where safety and efficiency are essential. The international research team, led by Prof. Liqiang Mai and Prof. Daping He from Wuhan University of Technology, Dr. Jinlong Yang from Shenzhen University, and Dr. Rui Tan from Swansea University, is continuing to refine their process. They are working on reducing the thickness of the graphene foils and enhancing their mechanical properties, while also exploring applications of this new material beyond Li-ion batteries, such as in redox flow batteries and sodium-ion batteries, with support from Professor Serena Margodonna’s group at Swansea University.
Reference: “Large-scale current collectors for regulating heat transfer and enhancing battery safety” by Lun Li, Jinlong Yang, Rui Tan, Wei Shu, CheeTong John Low, Zixin Zhang, Yu Zhao, Cheng Li, Yajun Zhang, Xingchuan Li, Huazhang Zhang, Xin Zhao, Zongkui Kou, Yong Xiao, Francis Verpoort, Hewu Wang, Liqiang Mai and Daping He, 5 August 2024, Nature Chemical Engineering.
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