Abstract:
The composite copper current collector, designed with a three-layer structure of "metal-polymer support layer-metal", significantly enhances the energy density of lithium-ion batteries by reducing copper usage by more than 50% and achieving lightweighting. Its longitudinal fracture and lateral insulation properties can prevent the spread of thermal runaway, simultaneously addressing the industry's contradiction between energy density and safety, and exhibits significant application potential in the new energy market. Its manufacturing process is divided into three categories: one-step method (all dry process, with the upgrade of magnetron sputtering equipment as the iterative direction, but with high equipment investment), two-step method (magnetron sputtering-electrochemical plating, the current mainstream of industrialization), and three-step method (magnetron sputtering-vacuum evaporation-electrochemical plating, where evaporation improves the integrity of the copper layer but is prone to damage the base film at high temperatures). Among these, the core of the manufacturing process is magnetron sputtering, which typically uses a roll-to-roll coating method. Research on the support layer of the composite copper current collector focuses on PP base films (low cost, resistant to electrolyte corrosion, and high elongation at break), but the non-polar surface of PP leads to insufficient interfacial bonding strength between PP and Cu. The modification schemes are divided into two types: in-situ surface modification (plasma etching and chemical etching, which enhance mechanical interlocking by increasing roughness and introducing polar functional groups, but have risks of time-dependent degradation and base film damage); and coating functional modification (such as TA-APTES nanospheres and PDA coatings, which achieve chemical bonding through C=O and N-H coordination with copper, and are more promising). The industrialization of composite copper current collectors needs to solve the problems of interface strengthening and process efficiency. Future research should integrate material innovation (such as functional coatings) and equipment upgrades to promote its large-scale application.