A breakthrough at the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) could reshape the future of electric vehicles (EVs).
ORNL scientists have unveiled a new type of current collector that could significantly speed up EV charging times, boost energy density, and reduce dependence on critical raw materials like copper.
This breakthrough could play a pivotal role in transforming the competitiveness of the American transportation sector.
Why fast EV charging is crucial
Improving EV charging times isn’t just about convenience – it’s a strategic necessity. For the United States to remain competitive in the global automotive market, developing domestically produced EV batteries that charge rapidly and support long-range driving is essential.
However, high energy density – a key requirement for longer trips – typically compromises charging speed and battery lifespan. Bridging this gap is crucial for large-scale EV adoption and manufacturing leadership.
The new current collector technology offers a way to overcome this trade-off, delivering both high energy density and the ability to handle extremely fast charging, restoring 80% of battery energy in just 10 minutes.
This has the potential to eliminate one of the biggest hurdles facing EV infrastructure today.
What is a current collector?
A current collector is a foundational component of every lithium-ion battery. It conducts electrical current from the battery’s active materials to the external circuit.
Typically, these are made from copper (for the anode) and aluminium (for the cathode), adding significant weight and cost to the battery pack.
Heavier batteries reduce vehicle efficiency and increase energy consumption, while the rising global demand for copper and aluminium creates supply chain vulnerabilities. ORNL’s innovation addresses both issues.
A lighter, cheaper, and more efficient current collector
In partnership with Soteria Battery Innovation Group, ORNL researchers developed a novel metalised polymer current collector.
It consists of a thin polymer core layered with ultra-thin copper or aluminium. This design slashes metal usage by up to 85%, reduces collector weight by 75%, and delivers 27% more energy per charge, enabling longer trips on a single charge.
Moreover, the new collector retains high performance even after 1,000 extreme fast-charge cycles – a scenario where traditional batteries often degrade rapidly. The result: longer battery life, faster charging, and a reduced need for critical raw materials.
Compatibility with mass production
A common barrier for battery innovations is scalability. Many alternatives to conventional current collectors require complex manufacturing methods incompatible with industry-standard roll-to-roll production. ORNL tackled this challenge head-on.
Researchers successfully integrated the new lightweight collector into coin and pouch cells using the same roll-to-roll methods found in commercial battery plants.
Despite the thinner material’s tendency to wrinkle, the team identified optimal processing parameters that make it viable for mass production. This paves the way for commercial adoption without requiring major infrastructure overhauls.
Enhanced safety through smart design
In addition to performance and cost benefits, the metalised polymer current collector enhances battery safety.
If a short circuit occurs, the plastic component of the collector melts, separating the metal layers and interrupting the current flow, effectively acting like a built-in circuit breaker. According to Soteria’s testing, this design reduces the risk of lithium-ion battery fires by up to 90%.
Accelerating America’s EV transition
This innovation, funded by the DOE’s Advanced Materials and Manufacturing Technologies Office (AMMTO), represents a critical step toward more sustainable, high-performance EV batteries.
By reducing dependence on imported metals and improving fast-charging capabilities, it aligns perfectly with national goals for energy security and industrial competitiveness.
As the EV market accelerates, technologies like this new current collector could define the next generation of American-made electric vehicles – faster, safer, and ready to compete on the global stage.
