8021 Aluminum Foil – High-Barrier Core Material for Soft Pack Batteries

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8021 aluminum foil is a specialized 8xxx series alloy (Al-Fe-Si) designed as the core barrier layer in lithium-ion soft pack battery aluminum-plastic film . It serves as the critical middle layer that prevents moisture ingress and electrolyte leakage, ensuring battery safety and longevity .

Key Applications

  • Soft pack lithium batteries for electric vehicles (EVs), 3C consumer electronics (smartphones, laptops), and energy storage systems.

  • Aluminum-plastic film composite structure: nylon outer layer / 8021 aluminum foil middle layer / polypropylene inner layer. 

Why 8021 Alloy?

PropertyAdvantage for Soft Pack Batteries
High elongation (15-26%)Enables deep drawing into complex battery shapes without cracking 
Excellent barrier propertiesPinhole density ≤5/m²; blocks moisture and oxygen 
Good deep drawabilityCupping value ≥7.0mm; withstands ≥5mm drawing depth --
Electrolyte corrosion resistanceDense oxide layer prevents degradation from LiPF₆ electrolytes -
High puncture resistanceWithstands internal electrode expansion and external impacts 

Technical Specifications


ParameterSpecification
Alloy8021
TemperO
Thickness0.025 – 0.045 mm (25-45 microns)
Thickness tolerance±0.002 mm
Width100 – 1,650 mm (customizable)
Tensile strength80 – 110 MPa
Elongation15% – 26% 
Cupping value≥7.0 mm
Pinhole density≤5 holes/m²
Residual oil on surface≤2 mg/m²
Wetting tension≥72 dyn/cm


Comparison with Other Alloys

AlloyElongationKey Advantage
802115-26%Best elongation; ideal for deep drawing -
807915-20%Similar performance, higher cost --
801112-20%Lower elongation, less suitable for complex shapes --
1235 8-15%Poor puncture resistance, prone to tearing 

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