Dexmet develops MicroGrid and PolyGrid precision expanded foils and polymers for high-performance applications and is now able to offer materials down to 25 micron in both aluminum and copper at widths up to 305 mm. These thinner materials coupled with the ability to produce very small openings in the material, should prove to be a well suited anode and cathode electrode solution for improved overall cell performance.
As an alternative to solid foils, these open area expanded materials will require less binder to adhere the active material to the electrode surface. The reduction in binder will result in better ion and electron flow for better rate capability and quicker recharge cycles. In addition, the volumetric reduction of binder is offset by more active material resulting in better energy density within the cell. Using an open area expanded product also improves the thermal properties of a cell by reducing the internal heat generated during the charge and discharge cycles, which plague so many of the current lithium ion designs today, creating an improvement in the overall life expectancy of the battery.