AC6757 LiNiCoMnO2 (NCM523) Double Side Coated Aluminum Foil

LiNiCoMnO2 (NCM523) Double Side Coated Aluminum Foil Description

The LiNiCoMnO2 (NCM523) Double-Side Coated Aluminum Foil is a high-performance composite electrode substrate designed for lithium-ion batteries, integrating a uniform NCM523 (LiNi0.5Co0.5Mn0.5O2) cathode layer on both sides of an aluminum foil core. The aluminum substrate, typically 10–20 μm thick, serves as a highly conductive current collector with low electrical resistivity (~2.65×10^-8 Ω·m) and robust mechanical properties, including tensile strength exceeding 150 MPa, ensuring structural integrity during electrode calendaring and cell assembly. Each NCM523 coating layer, with a thickness ranging from 50–120 μm, is composed of a balanced transition metal oxide (Ni:Co:Mn = 5:2:3) crystallizing in a layered α-NaFeO2 structure (space group *R-3m*). This layered configuration facilitates efficient lithium-ion intercalation and deintercalation, delivering a reversible specific capacity of ~160–180 mAh/g at 0.1C rates while maintaining moderate lattice strain (~2–3%) during cycling, which minimizes structural degradation.

The double-side coating process employs precision techniques such as slot-die coating or doctor-blading, followed by calendaring under controlled pressure (5–10 MPa) to achieve high electrode density (≥3.4 g/cm3) and uniform active material distribution. This symmetrical design doubles the active surface area compared to single-side configurations, significantly enhancing energy density and current distribution uniformity. The NCM523 layers are formulated with conductive additives (e.g., 3–5 wt% carbon black) and PVDF binders to optimize electronic percolation and interfacial adhesion, reducing charge-transfer resistance and enabling high-rate performance (e.g., ~140 mAh/g at 2C).

Thermal stability is a hallmark of NCM523, with oxygen release onset temperatures exceeding 220°C under inert conditions, attributed to manganese’s stabilizing role in suppressing oxygen evolution. Surface modifications, such as ultrathin Al2O3 coatings via atomic layer deposition (ALD) or trace dopants (e.g., Mg, Ti), further enhance interfacial stability by mitigating parasitic reactions and reducing electrolyte decomposition at high voltages (up to 4.4V). The balanced transition metal ratio also minimizes Li/Ni cation mixing (<4%) and mitigates phase transitions, contributing to long-term cycling stability (>90% capacity retention after 500 cycles at 1C). Advanced manufacturing protocols, including laser thickness control and plasma surface activation, ensure coating uniformity (thickness tolerance ±1.5 μm) and optimal porosity for electrolyte infiltration.

The double-side architecture, while increasing energy density, introduces challenges such as managing mechanical stress during electrode bending or stacking. However, the aluminum substrate’s inherent flexibility and corrosion resistance mitigate delamination risks, even under prolonged electrochemical cycling. This design also aligns with scalable production and recycling processes, where aluminum and NCM523 can be efficiently separated and regenerated. By harmonizing electrochemical efficiency, mechanical resilience, and thermal safety, the NCM523 Double-Side Coated Aluminum Foil represents a robust and versatile platform for advanced energy storage systems.

LiNiCoMnO2 (NCM523) Double Side Coated Aluminum Foil Applications

1. Electric Vehicles (EVs): NCM523 is a representative of medium-high nickel ternary materials for electric vehicle power batteries. Its energy density (~160-180 mAh/g) and thermal stability (oxygen release temperature >220°C) ensure safety while meeting range requirements. Through surface modification (e.g., sodium phytate coating) and elemental doping (e.g., Ti, Mg), it is possible to further increase the thermal runaway trigger temperature (from 125.9°C to 184.8°C) and achieve a capacity retention rate of 95% (500 cycles). Additionally, the recycled NCM523 material maintains its excellent performance after recycling, e.g., the recycled NCM523 cells with a soft pack have a capacity retention rate of 92% after 1000 cycles. For example, the capacity retention rate of recycled NCM523 soft pack battery reaches 92.7% after 1000 cycles.

2. Energy Storage System (ESS): NCM523 excels in grid energy storage and renewable energy integration. With optimized compaction density (≥3.0 g/cm3) and the introduction of lithium enrichment strategies (e.g., LiYO2 coating), its energy density can reach 300-350 Wh/kg for long-cycle charging and discharging scenarios. The regeneration process (e.g., acid leaching-co-precipitation) further reduces the cost and improves the economy, and the discharge capacity of the recycled material reaches 168.5 mAh /g (0.1C).

3. Consumer electronics: High-voltage NCM523 (cutoff voltage 4.5-4.9 V) significantly extends the battery life of smartphones, laptops, and other devices by inhibiting oxygen release and electrolyte decomposition through surface coating (e.g., cerium oxide). The modified material has a capacity retention rate of over 80% after 200 cycles at 4.9V.

4. Battery recycling and upgrading: Waste NCM523 can be regenerated through a variety of efficient processes. For example, the ball milling-spraying method regenerates materials with a discharge capacity of 159 mAh/g at 0.1C and a capacity retention rate of 91.55% after 100 cycles. Molten-salt restoration technology restores the material to its initial performance (161.2 mAh/g at 0.1C) by replenishing lithium with low-temperature co-molten salts. Not only are these methods environmentally friendly, but they also have a profitability that is about 10 times higher than traditional recycling.

5. High-power devices and hybrid systems: Nanostructured NCM523 (e.g., walnut-shaped nanosheets) optimize the lithium-ion diffusion path and provide a capacity of 131.23 mAh/g at 10C multiplication, which is suitable for high-power scenarios such as power tools, drones, and so on. In addition, NCM-derived heterostructures (e.g., NiCo-MOF@MnO2/AC electrodes) are used in asymmetric supercapacitors with both high specific capacitance (15.2 F /cm2) and energy density (1.191 mWh/cm2), which is suitable for hybrid energy storage systems.

6. High temperature and industrial applications: The NCM523's high temperature resistance (oxygen release temperature >220°C) makes it suitable for industrial machinery and backup power systems. Through lithium aluminate interfacial modification, the material's compacted density is increased to 3.3 g/cm3 while maintaining cycling stability at high temperatures.

LiNiCoMnO2 (NCM523) Double Side Coated Aluminum Foil Packaging

Our products are packaged in customized cartons of various sizes based on the material dimensions. Small items are securely packed in PP boxes, while larger items are placed in custom wooden crates. We ensure strict adherence to packaging customization and the use of appropriate cushioning materials to provide optimal protection during transportation.

Packaging: Carton, Wooden Box, or Customized.

Kindly review the packaging details provided for your reference.

Manufacturing Process

1.       Testing Method

(1)    Chemical Composition Analysis - Verified using techniques such as GDMS or XRF to ensure compliance with purity requirements.

(2)    Mechanical Properties Testing - Includes tensile strength, yield strength, and elongation tests to assess material performance.

(3)    Dimensional Inspection - Measures thickness, width, and length to ensure adherence to specified tolerances.

(4)    Surface Quality Inspection - Checks for defects such as scratches, cracks, or inclusions through visual and ultrasonic examination.

(5)    Hardness Testing - Determines material hardness to confirm uniformity and mechanical reliability.

Please refer to the SAM testing procedures for detailed information.

LiNiCoMnO2 (NCM523) Double Side Coated Aluminum Foil FAQs

Q1. Why is NCM preferred for high-energy applications?

NCM offers high energy density (>400 Wh/kg) and customizable electrochemical properties. For example, NCM811 delivers ~250 mAh/g capacity, ideal for electric vehicles (EVs). Advanced modifications, such as sodium phytate coatings, enhance thermal stability, delaying thermal runaway by 45% (from 125.9°C to 184.8°C).

Q2. What are the challenges of high-nickel NCM?

High nickel content (e.g., NCM811) increases energy density but risks oxygen loss at high voltages (>4.5V), causing phase transitions and microcracks. Solutions include high-entropy doping (Ti, Mg, Nb) to reduce strain (<0.5%) and coatings to suppress oxygen release.

Q3. What future advancements are expected?

Cobalt-free designs: Using Al or rare earths to reduce costs.

Ultra-high voltage: Stable operation up to 4.9V with advanced electrolytes.

Hybrid systems: NCM-based supercapacitors for rapid energy delivery.

Related Information

1.       Common Preparation Methods

The fabrication of LiNiCoMnO2 (NCM523) double-side coated aluminum foil involves a multi-step process integrating cathode material synthesis, slurry preparation, and precision coating techniques. The NCM523 cathode powder (LiNi0.5Co0.2Mn0.3O2) is typically synthesized via co-precipitation, where aqueous solutions of nickel sulfate (NiSO4·6H2O), cobalt sulfate (CoSO4·7H2O), and manganese sulfate (MnSO4·H2O) are mixed in a 5:2:3 molar ratio under controlled pH (10–12) and temperature (50–60°C) to precipitate a hydroxide precursor (Ni0.5Co0.2Mn0.3(OH)2). This precursor is then blended with lithium hydroxide (LiOH·H2O) in a lithium-to-transition-metal molar ratio of 1.05:1 and calcined at 900–950°C for 12–15 hours under oxygen flow to form the layered oxide structure.

For electrode fabrication, the NCM523 powder is combined with conductive carbon additives (e.g., 3–5 wt% Super P) and a polyvinylidene fluoride (PVDF) binder dissolved in N-methyl-2-pyrrolidone (NMP) to form a homogeneous slurry. The slurry is uniformly coated onto both sides of pre-treated aluminum foil (10–20 μm thickness) using slot-die coating or doctor-blade techniques, ensuring precise control over coating thickness (50–120 μm per side). The coated foil undergoes drying at 80–120°C to remove solvents, followed by calendaring under 5–10 MPa pressure to enhance electrode density (≥3.4 g/cm³) and adhesion. Key innovations include plasma treatment or chemical etching of the aluminum surface to improve slurry wettability and interfacial bonding, as well as post-coating thermal annealing (200–300°C) to reduce residual stress and stabilize the cathode layer.

Advanced methods like high-entropy doping (e.g., Ti, Mg, Nb) during precursor synthesis enhance lattice stability, while atomic layer deposition (ALD) of Al2O3 or wet-chemical coatings (e.g., sodium phytate) are applied to suppress oxygen release and electrolyte decomposition. Quality assurance involves laser thickness monitoring (±1.5 μm tolerance) and peel strength testing (>2.0 N/cm) to ensure uniformity and mechanical durability. This process balances scalability and performance, enabling mass production of high-energy-density electrodes for applications requiring robust electrochemical and thermal stability.