Senior Material (Europe) AB: Cutting-edge Separator Films to Transform the Battery Industry

The applications for high-powered lithium-ion cells are on the rise, increasing the emphasis on their safety and reliability. One of the most crucial components contributing to their safety is the cell separator, a thin, porous membrane that facilitates ion transport between the anode and cathode while preventing short circuits and overheating. The quality and design of these separators are imperative to a battery’s capacity and life cycle and are integral to its overall safety profile. In this context, partnering with experts in separator design becomes indispensable for businesses navigating the evolving landscape of lithium-ion technology.

Senior Material (Europe) AB is a prominent supplier of separator films in the lithium-ion battery sector, known for its advanced technology that guarantees a secure and dependable energy flow within batteries. It has the ability to manufacture the finest separator film, with a thickness of 5 micrometers in mass production, as well as a single ultra-thin coating layer down to 0.5 micrometers. Senior Material (Europe) AB works closely with its customers to create innovative solutions, processes, and materials that push the boundaries within battery lifetime, safety, and reliability.

“We are dedicated to establishing a strong local base, using our expertise and technological know-how to provide the finest separator film to an expanding network of European and global battery manufacturers rapidly and on a large scale,” says Jason Hai, CEO of Senior Material (Europe) AB. The company’s product portfolio consists of three types of separator films—dry separators, wet separators, and coated separators. For the dry-process separators, polymers are melted and unidirectionally stretched. This method is cost-effective and allows for customization options while also providing high mechanical strength. In addition, the pore structure of separators produced through this process is more uniform than those produced through the wet process.

Wet-process separator films undergo stretching in two directions, yielding excellent mechanical strength and low resistance. These membranes enhance energy density, strength, and safety in lithium-ion batteries.

The coated separator films, whether dry or wet processed, may incorporate one or more coated layers to enhance functionality, addressing specific customer needs for heat resistance, long-term cyclability, and safety. The technology employed in these films guarantees thermal stability and minimizes self-discharge, thus meeting various manufacturing demands and achieving the desired performance of batteries.

Senior Material (Europe) AB emphasizes maintaining clean production conditions for battery manufacturing. The preparation of the slurry (the mixture for coating the separator film), the coating process, and the slitting of the coated separator film all occur in clean rooms that resemble laboratories rather than industrial settings. The appropriate temperature, air humidity, and a particle-free environment are crucial to ensuring that the separator film possesses the necessary qualities for a secure and efficient energy flow in lithium-ion batteries. The commitment to stringent control extends beyond external suppliers, encompassing internal production processes, where effective detection measures are implemented to identify and eliminate any instances of contamination.

The development process involves collaboration between battery manufacturers, wherein various components are combined to create a customized product tailored to meet customer requirements. These products undergo a comprehensive testing phase spanning 18 months that includes multiple stages (A, B, C, D, and samples) to guarantee the quality and performance of the batteries.

Throughout this period, varying quantities of the product, incorporating the latest recipe modifications, are provided to the customer for thorough testing. Following the finalization of the product, negotiations for long-term contracts ensue, which typically extend over six, nine, or even ten years, fostering strong bonds with end-users and battery manufacturers. The intricate co-development process requires prolonged technical and quality meetings with customers, often taking over a year to yield results and navigate through the sample stages.
Senior Material (Europe) AB is also continually exploring various offerings to introduce to the market due to the ongoing developments in the electric vehicle (EV) industry. It aims to identify products best suited for various product applications, considering the dynamic landscape of the EV sector.

SSenior Material (Europe) AB has 20 years of experience and is enthusiastic about contributing to an industry that stands out as a vital player in achieving climate targets. Senior Material (Europe) AB currently boasts around 150 employees. With ambitious plans to expand its workforce to approximately 600 in the coming years, Senior Material (Europe) AB aims to further align itself with the positive trajectory of the EV industry.

“With over 500 patents, we take pride in our pivotal role in advancing battery components, especially separator film development. As one of the world’s largest manufacturers, we’re excited to contribute to electrification, driving positive change in a rapidly evolving landscape,” concludes Henrik Kragh, sales director of Senior Material (Europe) AB.