Aluminium Foil (Battery Grade)
Battery-grade aluminium foil used as the cathode current collector in lithium-ion cells. Requires controlled alloy temper, thickness, surface treatment and cleanliness for high-speed cathode coating.
Overview
Cathode current collectors in automotive Li-ion cells are almost universally aluminium foil, typically ~12–20 µm (trending thinner), because aluminium is stable at cathode potentials where copper would dissolve. Battery foils are usually from AA1xxx or specialised alloys with tight gauge tolerance, controlled roughness, and carbon or primer coatings in some high-adhesion or high-rate designs. The foil must survive slurry coating, drying, calendaring and electrolyte exposure without pitting or delamination. Aluminium’s lower density versus copper helps pack gravimetric energy, while cost and rolling capacity are generally less constrained than ultra-thin copper anode foils. This entry covers battery cathode collector foil, not packaging foil or structural sheet aluminium.
Automotive Applications
Similar Materials
Copper Foil (Battery Grade)
Battery Current Collector
Ultra-thin electrodeposited or rolled copper foil used as the anode current collector in lithium-ion cells. Battery-grade foils demand tight thickness, roughness, tensile and purity control for high-speed coating lines.
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Properties
Category
Type
Battery Current Collector
Available Colors
Available Forms
Key Properties
- Electrochemically stable at cathode potentials
- Typical thickness ~12–20 µm for automotive cells
- Low density vs copper collectors
- Tight gauge and surface control for coating lines
- Optional carbon/primer coatings for adhesion
- Distinct from packaging or BIW aluminium products
Technical Specifications
Density
2.70 g/cm³
Tensile Strength
~150–250 MPa depending on alloy/temper for battery foil grades
Temperature Resistance
Melts ~660°C; electrode process and pack temperatures well within foil capability
Sustainability
Sustainability Rating
Aluminium foil scrap is readily recycled. Primary aluminium is energy-intensive, so low-carbon smelting and high scrap ratios improve the cathode collector footprint. Lower mass than copper collectors benefits pack-level sustainability metrics.