Current collectors are a critical component of a battery. Used to bridge batteries and external circuits, they are responsible for the flow of electrons between the negative and the positive terminals of the battery (electrodes), which directly influence the charge rate capability, battery capacity and the useful lifespan of the cell. Unfortunately, the market suffers from poor adhesion, high degradation, severe corrosion issues, and increased contact resistance. Today, bare aluminium is typically used as current collector, however, carbon-coated current collectors are increasing in popularity due to the performance advantages offered in energy and power density. This project aims to validate GNN-coatings technology in a continuous roll-to-roll environment and then produce cylindrical cells the performance. Having established a UK-based value chain, the project will increase GNN's manufacturing readiness level of production facilities in the UK by engaging all stakeholders. The innovative coated current collector improves adhesion and contact between the battery material and foil, enabling increased performance over competitors. Further, the technology which is produced using a rapid and low-energy process lowers production costs significantly. GNN's proprietary formulation uses organic polymers and binders and conductive material to reduce contact resistance, prevent corrosion, and increase adhesion. These advantages make the battery industry more competitive and sustainable for EV applications but also for mobile devices and energy storage systems requiring high electrical performance.

Current lithium-ion battery technology uses metal foil current collectors (copper, aluminium) sourced from large manufacturers based in Japan and China; there are no domestic UK suppliers, and all current collectors are imported. Existing current collectors are bulky and account for up to 30% of the total battery weight, reducing the gravimetric energy and power density. Replacing the metal sheet with a composite polymer conductive thin-film (polymer matrix containing electrically conductive particles) to reduce weight is a logical step forward. The vision for our collaborative project CONDUCTOR is to develop a lightweight and low-cost polymer current collector to replace the aluminium and copper foil current collectors used in lithium-ion batteries (LIB). Such batteries are one of the heaviest and most expensive components in a Battery Electric Vehicle (BEV). We estimate our polymer current collector will save some 4kg weight in a typical 50Kg automotive battery pack thereby increasing its charge and power density. Given there are no UK manufacturers of LIB current collectors, our ambition is to supply the growing need for LIB current collectors in line with growth of the Giga Factories in the UK to support the transition to 100% battery electric vehicle manufacture by 2035\.