Recent Development of Polyolefin-Based Microporous Separators for Li-Ion Batteries: A Review

Solvent Co-Intercalation Reactions for Batteries and Beyond

Solvent co-intercalation is a process in which ions and solvents jointly intercalate into a layered electrode material during battery charging/discharging. It typically leads to rapid electrode degradation, but new findings show that it can be highly reversible, lasting several thousand cycles. Solvent co-intercalation has two important characteristics: (1) the charge transfer resistance is minimized as stripping of the solvation shell is eliminated and (2) the fact that solvents become part of the electrode reaction provides another means of designing electrode materials. The concept of solvent co-intercalation is chemically very diverse, as a single electrode material can host different types and numbers of solvents and ions. It is likely that many undiscovered combinations of electrode materials, solvents, and ions capable of solvent co-intercalation reactions exist, offering a largely unexplored chemical space for new materials. Co-intercalation can expand the crystal lattice (>1 nm) to the extent that free solvents are present in the structure, forming a layered, "porous" material. This indicates that the concept has a much broader impact and relates to other research fields such as supercapacitors, layered nanostructures, and nanocatalysis. This Review covers the concept and current understanding of solvent co-intercalation reactions, characterization methods, advantages, limitations, and future research directions.

Functional Polyolefins and Composites

Polyolefins are simple hydrocarbons that require additional chemical modifications or functional additives to give them custom functions. Recent research in the development of functional polyolefins has surpassed the traditional approach of simply improving surface properties by incorporating polar moieties. Creating custom functionalized polyolefins by using specific functional units has attracted increasing attention. This review summarizes advances in preparing custom functionalized polyolefin materials using functional units such as comonomers, chain-transfer agents, post-polymerization modification reagents, and functional fillers. Exploring new functional units and innovative synthetic strategies will further enhance the performance and expand the applications of functional polyolefins.

Efficient mitigation of lithium dendrite by two-dimensional A-type molecular sieve membrane for lithium metal battery

Uneven lithium deposition poses a primary challenge for lithium-ion batteries, as it often triggers the growth of lithium dendrites, thereby significantly compromising battery performance and potentially giving rise to safety concerns. Therefore, the high level of safety must be guaranteed to achieve the large-scale application of battery energy storage systems. Here, we present a novel separator design achieved by incorporating a two-dimensional A-type molecular sieve coating onto the polypropylene separator surface, which functions as an effective lithium ion redistribution layer. The results demonstrated that even after undergoing 1000 cycles, the cell equipped with a two-dimensional A-type molecular sieve-Polypropylene (2D-A-PP) separator still maintains an impressive capacity retention rate of 70 %. In contrast, cells equipped with Polypropylene (PP) separators exhibit capacity retention rates below 50 % after only 500 cycles. Additionally, the incorporation of a two-dimensional molecular sieve enhances the mechanical properties of the PP separator, thereby bolstering battery safety. This study proposes a novel concept for the design of lithium-ion battery separator materials, offering a fresh perspective on the development of separators with exceptional thermal stability, enhanced porosity, superior electrolyte affinity, and effective inhibition of lithium dendrite formation.

From Lithium-Ion to Sodium-Ion Batteries for Sustainable Energy Storage: A Comprehensive Review on Recent Research Advancements and Perspectives

A significant turning point in the search for environmentally friendly energy storage options is the switch from lithium-ion to sodium-ion batteries. This review highlights the potential of sodium-ion battery (NIB) technology to address the environmental and financial issues related to lithium-ion systems by thoroughly examining recent developments in NIB technology. It is noted that sodium is more abundant and less expensive than lithium, NIBs have several benefits that could drastically lower the total cost of energy storage systems. In addition, this study examines new findings in important fields including electrolyte compositions, electrode materials, and battery performances of lithium-ion batteries (LIBs) and NIBs. The article highlights advancements in anode and cathode materials, with a focus on improving energy density, cycle stability, and rate capability of both LIBs and NIBs. The review also covers the advances made in comprehending the electrochemical mechanisms and special difficulties associated with NIBs, such as material degradation and sodium ion diffusion. Future research directions are discussed, with an emphasis on enhancing the scalability and commercial viability of sodium-ion technology over lithium on Electric Grid. Considering sustainability objectives and the integration of renewable energy sources, the review's assessment of sodium-ion batteries' possible effects on the future state of energy storage is included in its conclusion.

Bacterial Cellulose Applications in Electrochemical Energy Storage Devices

Bacterial cellulose (BC) is produced via the fermentation of various microorganisms. It has an interconnected 3D porous network structure, strong water-locking ability, high mechanical strength, chemical stability, anti-shrinkage properties, renewability, biodegradability, and a low cost. BC-based materials and their derivatives have been utilized to fabricate advanced functional materials for electrochemical energy storage devices and flexible electronics. This review summarizes recent progress in the development of BC-related functional materials for electrochemical energy storage devices. The origin, components, and microstructure of BC are discussed, followed by the advantages of using BC in energy storage applications. Then, BC-related material design strategies in terms of solid electrolytes, binders, and separators, as well as BC-derived carbon nanofibers for electroactive materials are discussed. Finally, a short conclusion and outlook regarding current challenges and future research opportunities related to BC-based advanced functional materials for next-generation energy storage devices suggestions are proposed.

Stable anode/separator interface enabled by graft modification of polypropylene separator via electron beam irradiation technique toward high-performance sodium metal batteries

Sodium metal batteries (SMBs) are considered as strong alternatives to lithium-ion batteries (LIBs), due to the inherent merits of sodium metal anodes (SMAs) including low redox potential (-2.71 V vs. SHE), high theoretical capacity (1166 mAh g-1), and abundant resources. However, the uncontrollable Na dendrite growth has significantly impeded the practical deployment of SMBs. Separator modification has emerged as an effective strategy for substantially enhancing the performance of SMAs. Herein, for the first time, we present the successful grafting polyacrylic acid (PAA) onto polypropylene (PP) separators (denoted as PP-g-PAA) using highly efficient electron beam (EB) irradiation to improve the cyclability of SMAs. The polar carboxyl groups of PAA can facilitate the electrolyte wetting and provide ample mechanical strength to resist dendrite penetration. Consequently, the regulation of Na+ ion flux enables uniform Na+ deposition with dendrite-free morphology, facilitated by the favorable anode/separator interface. The PP-g-PAA separator significantly enhances the cyclability of fabricated cells. Notably, the lifespan of Na||Na symmetric cells can be extended up to 5519 h at 1 mA cm-2 and 1 mAh cm-2. The stable design of the anode/separator interface achieved through polyolefin separator modification presented in this study holds promise for the further advancement of next-generation advanced battery systems.

High-Viscosity Phase Inversion Separators for Freestanding and Direct-on-Electrode Manufacturing in Lithium-Ion Batteries

Separators play a critical role in lithium-ion batteries (LIBs) by facilitating lithium-ion (Li-ion) transport while enabling safe battery operation. However, commercial separators made from polypropylene (PP) or polyethylene (PE) impose a discrete processing step in current LIB manufacturing as they cannot be manufactured with the same slot-die coating process used to fabricate the electrodes. Moreover, commercial separators cannot accommodate newer manufacturing processes used to produce leading-edge microbatteries and flexible batteries with customized form factors. As a path toward rethinking LIB fabrication, we have developed a high-viscosity polymer composite separator slurry that enables the fabrication of both freestanding and direct-on-electrode films. A streamlined phase inversion process is used to impart porosity in cast separator films upon drying. To understand the impacts of material composition and rheology on phase inversion processing and separator performance, we investigated four different separator formulations. We used either diethylene glycol (DEG) or triethyl phosphate (TEP) as a nonsolvent, and either silica (SiO2) or alumina (Al2O3) as an inorganic additive in a polyvinylidene fluoride-co-hexafluoropropylene (PVDF-HFP) matrix. Through a down-selection process, we developed a TEP-SiO2 separator formulation that matched or outperformed a commercial Celgard 2325 (PP/PE/PP) separator and a Beyond Battery ceramic-coated PE (CC/PE/CC) separator under rate and cycle life tests in LiFePO4|Li4Ti5O12 (LFP|LTO) and LiNi0.5Mn0.3Co0.2O2|graphite (NMC-532|graphite) coin cells at C/10-1C rates. Our TEP-SiO2 slurry had a viscosity of 298 Pa s at a 1 s-1 shear rate and shear-thinning behavior. When deposited directly onto an LTO anode and cycled against an LFP cathode, the direct-on-electrode TEP-SiO2 separator increased the specific capacity by 58% and 304% at 2C rates relative to the PP/PE/PP and CC/PE/CC separators, respectively. Additionally, the freestanding TEP-SiO2 separator maintained dimensional stability when heated to 200 °C for 1 h and demonstrated a higher elastic modulus and hardness than the PP/PE/PP and CC/PE/CC separators when measured with nanoindentation.

Engineering Polymer-Based Porous Membrane for Sustainable Lithium-Ion Battery Separators

Due to the growing demand for eco-friendly products, lithium-ion batteries (LIBs) have gained widespread attention as an energy storage solution. With the global demand for clean and sustainable energy, the social, economic, and environmental significance of LIBs is becoming more widely recognized. LIBs are composed of cathode and anode electrodes, electrolytes, and separators. Notably, the separator, a pivotal and indispensable component in LIBs that primarily consists of a porous membrane material, warrants significant research attention. Researchers have thus endeavored to develop innovative systems that enhance separator performance, fortify security measures, and address prevailing limitations. Herein, this review aims to furnish researchers with comprehensive content on battery separator membranes, encompassing performance requirements, functional parameters, manufacturing protocols, scientific progress, and overall performance evaluations. Specifically, it investigates the latest breakthroughs in porous membrane design, fabrication, modification, and optimization that employ various commonly used or emerging polymeric materials. Furthermore, the article offers insights into the future trajectory of polymer-based composite membranes for LIB applications and prospective challenges awaiting scientific exploration. The robust and durable membranes developed have shown superior efficacy across diverse applications. Consequently, these proposed concepts pave the way for a circular economy that curtails waste materials, lowers process costs, and mitigates the environmental footprint.

Recent Advances in the Support Layer, Interlayer and Active Layer of TFC and TFN Organic Solvent Nanofiltration (OSN) Membranes: A Review

Although separation of solutes from organic solutions is considered a challenging process, it is inevitable in various chemical, petrochemical and pharmaceutical industries. OSN membranes are the heart of OSN technology that are widely utilized to separate various solutes and contaminants from organic solvents, which is now considered an emerging field. Hence, numerous studies have been attracted to this field to manufacture novel membranes with outstanding properties. Thin-film composite (TFC) and nanocomposite (TFN) membranes are two different classes of membranes that have been recently utilized for this purpose. TFC and TFN membranes are made up of similar layers, and the difference is the use of various nanoparticles in TFN membranes, which are classified into two types of porous and nonporous ones, for enhancing the permeate flux. This study aims to review recent advances in TFC and TFN membranes fabricated for organic solvent nanofiltration (OSN) applications. Here, we will first study the materials used to fabricate the support layer, not only the membranes which are not stable in organic solvents and require to be cross-linked, but also those which are inherently stable in harsh media and do not need any cross-linking step, and all of their advantages and disadvantages. Then, we will study the effects of fabricating different interlayers on the performance of the membranes, and the mechanisms of introducing an interlayer in the regulation of the PA structure. At the final step, we will study the type of monomers utilized for the fabrication of the active layer, the effect of surfactants in reducing the tension between the monomers and the membrane surface, and the type of nanoparticles used in the active layer of TFN membranes and their effects in enhancing the membrane separation performance.

A Systematic Study on the Effects of Solvating Solvents and Additives in Localized High-Concentration Electrolytes over Electrochemical Performance of Lithium-Ion Batteries

Localized high-concentration electrolytes (LHCEs) based on five different types of solvents were systematically studied and compared in lithium (Li)-ion batteries (LIBs). The unique solvation structure of LHCEs promotes the participation of Li salt in forming solid electrolyte interphase (SEI) on graphite (Gr) anode, which enables solvents previously considered incompatible with Gr to achieve reversible lithiation/delithiation. However, the long cyclability of LIBs is still subject to the intrinsic properties of the solvent species in LHCEs. Such issue can be readily resolved by introducing a small amount of additive into LHCEs. The synergetic decompositions of Li salt, solvating solvent and additive yield effective SEIs and cathode electrolyte interphases (CEIs) in most of the studied LHCEs. This study reveals that both the structure and the composition of solvation sheaths in LHCEs have significant effect on SEI and CEI, and consequently, the cycle life of energetically dense LIBs.

A Review of Nonaqueous Electrolytes, Binders, and Separators for Lithium-Ion Batteries

Lithium-ion batteries (LIBs) are the most important electrochemical energy storage devices due to their high energy density, long cycle life, and low cost. During the past decades, many review papers outlining the advantages of state-of-the-art LIBs have been published, and extensive efforts have been devoted to improving their specific energy density and cycle life performance. These papers are primarily focused on the design and development of various advanced cathode and anode electrode materials, with less attention given to the other important components of the battery. The “nonelectroconductive” components are of equal importance to electrode active materials and can significantly affect the performance of LIBs. They could directly impact the capacity, safety, charging time, and cycle life of batteries and thus affect their commercial application. This review summarizes the recent progress in the development of nonaqueous electrolytes, binders, and separators for LIBs and discusses their impact on the battery performance. In addition, the challenges and perspectives for future development of LIBs are discussed, and new avenues for state-of-the-art LIBs to reach their full potential for a wide range of practical applications are outlined.

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High-Performance and Highly Safe Solvate Ionic Liquid-Based Gel Polymer Electrolyte by Rapid UV-Curing for Lithium-Ion Batteries

Utilizing ionic liquids (ILs) with low flammability as the precursor component for a gel polymer electrolyte is a smart strategy out of safety concerns. Solvate ionic liquids (SILs) consist of equimolar lithium bis(trifluoromethylsulfonyl)imide and tetraglyme, alleviating the main problems of high viscosity and low Li⁺ conductivity of conventional ILs. In this study, within a very short time of 30 s, a SIL turns immobile using efficient and controllable UV-curing with an ethoxylated trimethylolpropane triacrylate (ETPTA) network, forming a homogeneous SIL-based gel polymer electrolyte (SGPE) with enhanced thermal stability (216 °C), robust mechanical strength (compression modulus: 1.701 MPa), and high ionic conductivity (0.63 mS cm^-1 at room temperature). A Li|SGPE|LiFePO₄ cell demonstrates high charge/discharge reversibility and cycling stability with a capacity retention rate of 99.7% after 750 cycles and an average Coulombic efficiency of 99.7%, owing to its excellent electrochemical compatibility with Li-metal. A close-contact electrode/electrolyte interface is formed by in situ curing of the electrolyte on the electrode surface, which enables the pouch full cell to work stably under the conditions of cutting/bending. In view of the excellent mechanical, thermal, and electrochemical performances of SGPE, it is believed to be a promising gel polymer electrolyte for constructing high-safety lithium-ion batteries (LIBs).

Fabrication and Investigation of PE-SiO2@PZS Composite Separator for Lithium-Ion Batteries

Commercial polyolefin separators exhibit problems including shrinkage under high temperatures and poor electrolyte wettability and uptake, resulting in low ionic conductivity and safety problems. In this work, core–shell silica-polyphosphazene nanoparticles (SiO₂@PZS) with different PZS layer thicknesses were synthesized and coated onto both sides of polyethylene (PE) microporous membranes to prepare composite membranes. Compared to pure silica-coated membranes and PE membranes, the PE-SiO₂@PZS composite membrane had higher ionic conductivity. With the increase in the SiO₂@PZS shell thickness, the electrolyte uptake, ionic conductivity and discharge capacity gradually increased. The discharge capacity of the PE-SiO₂@PZS composite membrane at 8 C rate was 129 mAh/g, which was higher than the values of 107 mAh/g for the PE-SiO₂ composite membrane and 104 mAh/g for the PE membrane.

Ion Substitution Strategy of Manganese-Based Layered Oxide Cathodes for Advanced and Low-Cost Sodium Ion Batteries

Sodium ion batteries (SIBs) have recently been promising in the large-scale electric energy storage system, due to the low cost, abundant sodium resources. Mn-based layered oxide cathode materials have been widely investigated, because of the high theoretical specific capacity, low cost, and abundant reserves. However, their development is limited by the problems of Jahn-Teller distortion, Na⁺ /vacancy ordering, complex phase transitions, and irreversible anionic redox during cycling. Ion substitution strategy is one simple and effective way to regulate the crystal structure and boost sodium-storage performances of Mn-based cathode materials. In this review, we summarize the progress and mechanism of ion-substituted Mn-based oxides, establish a composition-crystal structure-electrochemical performance relationship, and also offer perspectives for guiding the design of high-performance Mn-based oxides for SIBs.

A Review on the Prediction of Health State and Serving Life of Lithium-Ion Batteries

The monitoring and prediction of the health status and the end of life of batteries during the actual operation plays a key role in the battery safety management. However, although many related studies have achieved exciting results, there are few systematic and comprehensive reviews on these prediction methods. In this paper, the current prediction models of remaining useful life of lithium-ion batteries are divided into mechanism-based models, semi-empirical models and data-driven models. Their advantages, technical obstacles, improvement methods and prediction performance are summarized, and the latest research results are shown by comparison. We highlight that the fusion models of convolution neural network, long short term memory network and so on, which have great practical application prospects because of their outstanding computing efficiency and strong modeling ability. Finally, we look forward to the future work in simplifying the model and improving its interpretability.

From Materials to Cell: State-of-the-Art and Prospective Technologies for Lithium-Ion Battery Electrode Processing

Electrode processing plays an important role in advancing lithium-ion battery technologies and has a significant impact on cell energy density, manufacturing cost, and throughput. Compared to the extensive research on materials development, however, there has been much less effort in this area. In this Review, we outline each step in the electrode processing of lithium-ion batteries from materials to cell assembly, summarize the recent progress in individual steps, deconvolute the interplays between those steps, discuss the underlying constraints, and share some prospective technologies. This Review aims to provide an overview of the whole process in lithium-ion battery fabrication from powder to cell formation and bridge the gap between academic development and industrial manufacturing.

A Gel Polymer Electrolyte Reinforced Membrane for Lithium-Ion Batteries via the Simultaneous-Irradiation of the Electron Beam

In this research, a series of innovative and stable cross-linked gel polymer reinforced membranes (GPRMs), were successfully prepared and investigated for application in lithium-ion batteries. Herein, a gel directly within the commercial polyethylene (PE) separator is supported via electron-beam simultaneous irradiation cross-linking of commercial liquid electrolyte and poly(ethylene glycol) methacrylate (PEGMA) oligomers. The physical and electrochemical properties of the GPRMs were characterized by SEM, TEM, mechanical durability, heating shrinkage, and ion conductivity, etc. The GPRMs demonstrated excellent mechanical durability and high ion conductivity compared with traditional PE membranes. Moreover, coin-typed cells were assembled and cycle performance was also studied compared with same-typed cells with commercial PE membrane and liquid electrolyte. As a result, the coin-typed cells using GPRMs also showed a relatively good efficiency on the 50th cycles at a high 1.0 C-rate. These GPRMs with excellent properties present a very promising material for utilization in high-performance lithium-ion batteries with improved safety and reliability.

PEI-SiO2 composite membranes with high thermal stability: Synthesis by self-assembled in situ growth and application in lithium-ion batteries

To improve the safety of lithium-ion batteries (LIBs), a polyether amide–silica (PEI-SiO2) composite membrane was developed by the in situ hydrolysis of tetraethylorthosilicate (TEOS) and its subsequent self-assembly on the surface of PEI fibers. Because of the presence of the SiO2 shell, the PEI-SiO2 composite membrane exhibited good thermal stability at high temperatures. The composite membrane did not change its color and size after heating at 200°C for 1 h as well as exhibited excellent flame retardancy. Moreover, the membrane maintained its high porosity even after the introduction of shell layers. The electrolyte is completely absorbed in the membrane within 0.5 s. The electrolyte uptake was up to 625%, and the ionic conductivity was up to 1.9 mS/cm at room temperature. Compared to the polyolefin membrane and the pure PEI membrane, the PEI-SiO2 composite membrane showed higher electrochemical stability, with an electrochemical window of up to 5.5 V. The battery assembled with the composite membrane showed excellent cycle stability, and the capacity retention rate was as high as 98.6% after 50 cycles. The LIBs based on the PEI-SiO2 composite membrane exhibited safe operation and high electrochemical performance, thus highlighting the applicability of the composite membrane in high-power batteries.