Perforated copper foil extends lithium-ion battery life fourfold

Scientists at the Moscow Institute of Physics and Technology have discovered a simple and technologically scalable way to significantly extend the lifespan of high-capacity lithium-ion batteries with silicon anodes – by replacing a solid metal current collector with perforated copper foil.

According to the official website of the Institute, lithium-ion batteries power electric vehicles, drones and portable electronics. While their energy density is approaching theoretical limits, global demand for more powerful and compact energy storage continues to grow.

One promising route beyond current limitations is replacing conventional graphite anodes with silicon. Silicon offers nearly ten times higher theoretical capacity, faster charging, improved low-temperature performance and the potential for thinner, more compact devices.

As silicon particles absorb and release lithium ions, the anode expands dramatically – increasing in volume by three to four times – before contracting again. This repeated swelling leads to cracking, delamination and eventual battery failure.

Laboratory experiments demonstrated that replacing solid copper foil with perforated foil preserved 60–90 per cent of the silicon-containing anode’s capacity after 100 charge–discharge cycles. A comparable stabilising effect was observed even when the discharge current was increased fourfold. Notably, smaller hole diameters delivered stronger stabilisation effects.

Importantly, the innovation can be implemented in industrial production immediately. The researchers deliberately used commercially available materials and manufacturing equipment commonly found in battery production facilities.

The development could significantly reduce the cost of next-generation compact and energy-dense batteries, strengthening the technological foundation for electric mobility, unmanned systems and advanced portable electronics, as reported by the source.