Unlocking the value of copper and aluminum foils from spent lithium-ion batteries

Recovering copper (Cu) and aluminum (Al) foils from spent lithium-ion batteries (LIBs) is a critical step in enhancing the sustainability of battery recycling and addressing the growing demand for these metals. However, the strong adhesion between the foils and active materials poses significant technical challenges, mainly due to the presence of polymeric binders such as polyvinylidene fluoride (PVDF). This review focuses on the separation mechanisms of Cu and Al foils, with special emphasis on the physical, chemical, and electrochemical processes that facilitate the separation of active materials from the collector. The existing methods and advances in the recovery and utilization of Cu/Al current collectors from spent LIBs are highlighted, including chemical dissolution, mechano-chemistry, thermal treatment, and electrochemical separation. The potential for reusing recovered Cu/Al in new LIBs or other industrial applications is also evaluated, emphasizing the importance of material purity and quality. Future directions for improving the recycling process are explored, focusing on innovative separation technologies and sustainable resource utilization strategies. This review seeks to provide a comprehensive understanding of the current state of Cu/Al foil recovery in LIBs recycling while offering insights into potential advances in this field.