PolyU breakthrough promises to cut the cost and break the performance bottleneck of ubiquitous Lithium-ion batteries, especially in booming electric vehicle market.
The future will be battery-powered. Our increasingly mobile-centric world is shifting to renewable energy to run everything from personal digital devices to electric vehicles. Now, a team of PolyU researchers led by Professor Zheng Zijian, Chair Professor of Soft Materials and Devices and Professor of the Department of Applied Biology and Chemical Technology, is leading the transformation. They are commercialising a breakthrough materials technology designed to cut the cost and boost the performance of widely used Lithium-ion batteries.
The timing is perfect. According to the international consulting firm, McKinsey & Company, global demand for Li-ion batteries will soar nearly seven-fold by 2030. At the same time, revenues throughout the battery value chain are expected to explode, from US$85 billion in 2022 to over US$400 billion in 2030, with active materials and cell manufacturing accounting for the largest revenue pools.
New Materials for New Energy
PolyU and Shanghai NIO signed an MoU to expedite the development of novel battery research.
Traditional Lithium-ion batteries use thin layers of copper or aluminium foil as “current collectors” (CCs) to conduct electricity during charging and discharging. Reducing the weight and thickness of these CCs is an effective way to shrink the size and increase the energy density of batteries. However, this approach has reached the mechanical limits of metals, making them more expensive to produce and easy to break.
Professor Zheng’s “Next-Generation Composite Current Collectors for Mobility and Energy Storage Batteries” project, has developed an ultrathin, ultralight, flexible and durable film made from carbon nanotubes instead of metal. It is 80% to 85% lighter and 65% to 80% thinner than metal foils, and costs 40% to 60% less. It also offers better electrical and thermal conductivity, as well as chemical and electrochemical stability than existing metal foils, while being more compatible with various electrode materials. The composite CC also boosts gravimetric energy density of LIBs by 20% to 25% and the volumetric energy density by 9% to 12%.
Other research teams around the world, and even some companies, are making so-called composite current collectors. “But, while they use polymer and polymer films, we use carbon nanotubes, which deliver very different material properties. Our batteries can be used anywhere, and they will last longer after charging, making them ideal for EV applications,” said Professor Zheng.
In addition, the composite current collectors offer an important energy storage advantage. “Many batteries are used in urban settings, such as within a building or a public area. In high-density environments like Hong Kong and other busy cities, smaller and lighter batteries can be a cheaper and more efficient solution,” he added.
Coming soon to an EV near you
The project was one of the first two PolyU initiatives to win funding from the Hong Kong Government’s Research, Academic and Industry Sectors One-plus Scheme (RAISe+) scheme, which aims to unleash the potential of local universities in the transformation and commercialisation of R&D outcomes. “Under this Scheme, research teams are entitled to at least 70% of the IP benefits, which is highly motivating for entrepreneurs, compared to other countries’ schemes that usually offer less than 50%,” Professor Zheng explained.
This is a powerful motivator for researchers to commercialise their innovations, bridging the gap between academic research and practical application. Professor Zheng is confident his team can take the concept from lab bench to pilot testing within two years, and begin mass production in the Mainland China market sometime in 2027.
He has already set up a startup, MatraVolt Limited, to focus on financing, while PolyU signed an MoU with Mainland’s premium smart EV manufacturer, Shanghai NIO Co., Ltd, last November. NIO is now partnering with the PolyU research team to test the new materials and provide expert feedback.
Research, Academic and Industry Sectors One-plus (RAISe+) Scheme Signing Ceremony
“Our technology could reduce the cost of an EV battery by about HK$5,000, which makes a big difference for end-users. Cars will be cheaper, and owners will be able drive longer and further,” said Prof. Zheng.
He believes new materials and new energy will open new economic possibilities, and help Hong Kong become an innovative, green centre, in-line with the national government’s “new quality productive forces” initiative.
“PolyU is committed to integrating the University’s research outcomes with mainland China’s industrial chains and markets, and boosting the development of new energy technology,” he said.
