IM speeds up in copper foil technology to curve battery thermal runaway

IM’s composite copper foil deposition equipment. [Courtesy of IM]

South Korean company IM has taken a notable step into the anode materials market for secondary batteries, accelerating the commercialization of composite copper foil. The company has installed equipment in Mado General Industrial Complex in Hwaseong and Ansan Industrial Complex in Ansan, aiming for mass production by the end of this year. Composite copper foil is known for its ability to prevent thermal runaway in electric vehicle batteries.

On Monday, industry sources said that IM recently signed a memorandum of understanding (MOU) with Chinese copper foil specialist Nuode New Materials for technology exchange related to composite copper foil. The two companies agreed to collaborate on the technologies needed for commercialization and to test IM’s prototypes with a major Chinese secondary battery manufacturer.

Nuode, which is listed on the Shanghai Stock Exchange, holds the largest market share in China’s copper foil market and possesses the technology to manufacture ultra-thin copper foil at 4 micrometers.

IM is developing a “two-step” process that includes vacuum deposition and electroplating. The company has received positive evaluations for its differentiated technology, which improves copper plating adhesion and wrinkle issues, overcoming limitations seen in technologies developed in China.

IM’s ongoing collaborations include Chinese copper foil producers like Nuode and Huachuang, both of which are major suppliers of battery-grade copper foil, directly invested in by battery giants CATL and BYD.

Composite copper foil replaces metallic copper with low-density polymer films such as polyethylene terephthalate (PET) and polypropylene (PP). This makes the material cheaper and lighter, enabling the development of high-capacity, long-life batteries while reducing the risk of thermal runaway, thus enhancing safety.

PET composite copper foil is over 60 percent lighter compared to conventional copper foil of the same thickness and area, and it improves battery energy density by 10 percent. Once yield stabilizes, production costs could be reduced by around 63 percent, while also solving thermal runaway concerns, thereby extending battery life, the company said.