Role in Lithium-Ion Batteries
Aluminum serves three distinct roles. First: aluminum foil (12–20 microns) is the cathode current collector — the substrate on which all cathode active materials are coated. Aluminum is chosen because cathode potentials are too high for copper to remain stable. Second, aluminum is used as the cell housing in pouch and prismatic cell formats. Third, aluminum alloys form battery module and pack structural components — cooling plates, enclosures, mounting hardware — where its strength-to-weight ratio is critical for EV applications.
Electrification multiplier: An EV battery pack uses approximately 20–30 kg of aluminum in structural and functional components. Battery-grade aluminum foil manufacturing — currently dominated by Japan and China — is a strategic priority for domestic cell manufacturing independence.