Secondary Battery Technologies

Ultra-Thin expanded metal foils for anode & cathode materials enhance performance in rechargeable battery and supercapacitor applications

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MicroGrid® Electrode Materials for Advanced Batteries

The lithium ion battery is a widely used rechargeable battery, popular due to its high energy density, high cell voltage, low self-discharge rate and lack of memory issues. The lithium ion battery, however, is also noted for poor cycle life, increased internal resistance with cycles and aging, and safety issues resulting from overheating during charging. Currently, lithium ion batteries, as depicted in Figure 1, are constructed using copper and aluminum foils for current collectors at the cathode and anode in thicknesses on the order of 7-25 microns. Expanded metal mesh used in place of the solid foils provides greater surface area per unit weight of metal in the battery. This results in better adhesion of the electrode layers and higher ion transport rate, thus greater energy density capability. Risk of overheating may also be reduced due to the increased surface area.

Dexmet has developed machines that can expand aluminum and copper foils down to 25 microns (.001") providing an opportunity for battery developers to utilize expanded products in their battery designs and realize the performance enhancements an open area product can provide. By incorporating MicroGrid materials, battery developers can overcome some of the limitations and disadvantages current lithium ion cells including:

  • Poor cycle life, especially under high current applications
  • Increased internal resistance with cycling and age
  • Safety issues if overheated or overcharged
  • Battery capacity insufficient for some applications

The development and utilization of expanded metal electrodes in the lithium ion battery can improve the ion transfer rate through the cell. This improved ion transfer rate can lower internal resistance and improve heat transfer thus resulting in lower internal operating temperature and improved charge and discharge rates.

MicroGrid® 25 Series Advantages

Utilizing an open area product will enhance the performance of the battery cell. Dexmet's MicroGrid® 25 can offer a number of performance advantages over solid foils.

coated expanded mesh

Increased Capacity at Higher C-Rates

The open area of the MicroGrid allows for more active material per thickness of the anode layer.

Reduced Capacity Fade

The porous foil allows lithium ions and electrolyte to completely saturate the multiple layer within a cell

Increased Battery Life

Better chemical bonding to the electrode using an open area product extending battery cycle life

Capacity Performance

Increase in capacity with MicrGrid 25 Series material compared to solid foils

Cycle Testing 1

Disruptive Technology for Advanced Battery Development

Disruptive Technology for Advanced Battery Development

Download this valuable guide using new developments in expanded material for advanced battery applications.


coated open area mesh

Coating Open Area Mesh

Coating an open area mesh is not something new.  Battery manufacturers have doing it for Primary battery electrode for the past 30 years. Depending on the viscosity of your active slurry, you may be able to coat MicroGrid 25 on your current coating equipment.  Typically, active slurries with 2,500Cp viscosity coat the best for coating one side at a time. For coating equipment that has the capability to coat both sides at the same time, viscosity does not pose as big of an issue.  

Learn More About MicroGrid 25

Let us explain the benefits of using an open area product in your secondary battery design. Contact one of our battery experts and start the conversation!