Plasma-assisted water-based Al2O3 ceramic coating for polyethylene-based microporous separators for lithium metal secondary batteries

Two-dimensional titania-assisted synthesis of flaky amorphous nano-alumina as a high-performance separator coating for lithium metal batteries

The polyolefin separators in lithium metal batteries face issues with low thermal stability, poor electrolyte wettability, and inferior mechanical properties. As a coating on polypropylene separators, flaky amorphous alumina is poised to promote mechanical properties and uniform lithium deposition with enhanced thermal stability, wettability, and Li+ transport, but the related study has been rarely conducted so far. This study introduces a flaky nano-alumina synthesized via a nanosheet-seeding method, showcasing its efficacy as a separator coating. The amorphous nano-alumina exhibits a high specific surface area of 228.1 m2/g, leading to exceptional electrolyte uptake (243 %), ionic conductivity (1.13 mS cm-1), and lithium-ion transference number (0.58). When integrated into LiFePO4||Li cells, the amorphous Al2O3-coated separators demonstrate superior rate performance and cycling stability. Moreover, Li||Li symmetric batteries exhibit excellent stability against lithium dendrite growth, achieving over 1000 h of stable cycling at 1 mA cm-2. Density functional theory (DFT) simulations indicate that the amorphous structure promotes Li+ ion diffusion and tolerates doping with foreign elements, positioning flaky amorphous nano-alumina as a promising material for high-performance battery coatings.

Effects of LATP Particle Size on the Residual Moisture of Separator Coating and the Performance of NCM811 Batteries

Li1+xAlxTi2-x(PO4)3 (LATP) is a NASICON-type solid electrolyte that presents stability in aqueous media and high ion conductivity. With these advantages, it is expected to be used as a cathode and separator coating material for lithium-ion batteries to improve battery performance. However, it also displays a high level of residual moisture introduction due to its strong water absorption. Meanwhile, LATP particle size is a key influential factor for the residual moisture level and thereby produces an impact on the battery performance. In this research, we prepared three different particle sizes of LATP (100, 500, and 1000 nm) to investigate their effects as separator coatings on residual moisture and NCM811 battery performance. The results indicate that the water absorption of LATP is much higher than that of Al2O3 with the same particle size; the use of nanoscale LATP keeps the residual moisture of the LATP/PE separator rather high. When the particle size is in the range of 100-1000 nm, the battery's cycling performance gradually deteriorates with the decrease of the particle size, among which the degradation of rate performance is more noticeable. More importantly, the research finds that LATP particles coated with polydopamine (PDA) can effectively reduce the coating's residual moisture. After being coated with PDA, LATP particles with a particle size of 1000 nm result in the residual moisture content within the composite separator decreasing from 2136 to 408 ppm, thereby contributing to the optimal performance of NCM811||Li and NMC811||C batteries.

Fabrication of Network Spherical α-Al2O3 and Its Application on the Separator of Lithium-Ion Batteries

Ceramic-coated polyolefin separator technology is considered a simple and effective method for the improvement of lithium-ion battery (LIB) safety. However, the characteristics of ceramic powder can adversely affect the surface structure and ion conductivity of the separators. Therefore, it is crucial to develop a ceramic powder that not only improves the thermal stability of the separators but also enhances ion conductivity. Herein, network spherical α-Al2O3 (N-Al2O3) with a multi-dimensional network pore structure was constructed. Furthermore, N-Al2O3 was applied as a coating to one side of polyethylene (PE) separators, resulting in N-Al2O3-PE separators that exhibit superior thermal stability and enhanced wettability with liquid electrolytes. Notably, the N-Al2O3-PE separators demonstrated exceptional ionic conductivity (0.632 mS cm-1), attributed to the internal multi-dimensional network pore structures of N-Al2O3, which facilitated an interconnected and efficient "highway" for the transport of Li+ ions. As a consequence, LiCoO2/Li half batteries equipped with these N-Al2O3-PE separators showcased remarkable rate and cycling performance. Particularly at high current densities, their discharge capacity and capacity retention rate significantly outperformed those of conventional PE separators.

Plasma Surface Treatment of Cu Current Collectors for Improving the Electrochemical Performance of Si Anodes

The practical utilization of Si electrodes is hindered by their substantial volume expansion during alloying and dealloying processes, which causes mechanical damage and separation from Cu current collectors. To alleviate the problem of Si composite detachment from Cu current collectors, the surface of the Cu current collectors is modified using atmospheric oxygen plasma. Plasma treatment improves the wetting ability of the Cu current collectors and, consequently, the coating quality of the Si electrodes. The uniform distribution of the Si electrode components reduces the sheet resistance and improves the adhesion properties of the Si electrodes containing surface-modified Cu current collectors. As a result, the volume expansion of Si during alloying and dealloying is reduced; this results in an excellent rate capability of 1584 mA h g-1 at a current density of 3.6 A g-1 (135% that of bare Cu) and excellent cycle performance of 1545 mA h g-1 after 300 cycles (Si electrodes with bare Cu exhibit 930 mA h g-1). Therefore, the developed plasma treatment method for Cu current collectors is expected to be an economical and efficient approach for improving the Li-ion battery performance.

Synergistic Effect of Dual-Ceramics for Improving the Dispersion Stability and Coating Quality of Aqueous Ceramic Coating Slurries for Polyethylene Separators in Li Secondary Batteries

We demonstrate that dispersion stability and excellent coating quality are achieved in polyethylene (PE) separators by premixing heterogeneous ceramics such as silica (SiO2) and alumina (Al2O3) in an aqueous solution, without the need for functional additives such as dispersing agents and surfactants. Due to the opposite polarities of the zeta potentials of SiO2 and Al2O3, SiO2 forms a sheath around the Al2O3 surface. Electrostatic repulsion occurs between the Al2O3 particles encapsulated in SiO2 to improve the dispersion stability of the slurry. The CCSs fabricated using a dual ceramic (SiO2 and Al2O3)-containing aqueous coating slurry, denoted as DC-CCSs, exhibit improved physical properties, such as a wetting property, electrolyte uptake, and ionic conductivity, compared to bare PE separators and CCSs coated with a single ceramic of Al2O3 (SC-CCSs). Consequently, DC-CCSs exhibit an improved electrochemical performance, in terms of rate capability and cycle performance. The half cells consisting of DC-CCSs retain 93.8% (97.12 mAh g−1) of the initial discharge capacity after 80 cycles, while the bare PE and SC-CCSs exhibit 22.5% and 26.6% capacity retention, respectively. The full cells consisting of DC-CCSs retain 90.9% (102.9 mAh g−1) of the initial discharge capacity after 400 cycles, while the bare PE and SC-CCS exhibit 64.7% and 73.4% capacity retention, respectively.

Achieve Stable Lithium Metal Anode by Sulfurized-Polyacrylonitrile Modified Separator for High-Performance Lithium Batteries

To develop a high-energy-density lithium battery, there still are several severe challenges for Li metal anode: low Coulombic efficiency caused by its high chemical reactivity, Li dendrite formation, and "dead" Li accumulation during repeated plating/stripping processes. Especially, lithium dendrite growth imposes inferior cycling stability and serious safety issues. Herein, we propose a facile but effective strategy to suppress lithium dendrite growth through an artificial inorganic-polymer protective layer derived from sulfurized polyacrylonitrile on a polyethylene separator. Benefiting from the lithiated sulfurized polyacrylonitrile and poly(acrylic acid), the flexible and ion-conductive protective layer could regulate Li⁺ flux and facilitate dendrite-free lithium deposition. Consequently, lithium metal with the meritorious protective layer can achieve a long-term cycling with negligible overpotential rise in Li-Li symmetric cells, even at a high areal capacity of 5 mAh cm^-2. Remarkably, such a protective layer enables stable cycling performance of Li-S cell with a high areal capacity (∼9 mAh cm^-2). This work provides a valuable exploration strategy for potential industrial applications of high-performance lithium metal batteries.

Surface-Functionalized Separator for Stable and Reliable Lithium Metal Batteries: A Review

Metallic Li has caught the attention of researchers studying future anodes for next-generation batteries, owing to its attractive properties: high theoretical capacity, highly negative standard potential, and very low density. However, inevitable issues, such as inhomogeneous Li deposition/dissolution and poor Coulombic efficiency, hinder the pragmatic use of Li anodes for commercial rechargeable batteries. As one of viable strategies, the surface functionalization of polymer separators has recently drawn significant attention from industries and academics to tackle the inherent issues of metallic Li anodes. In this article, separator-coating materials are classified into five or six categories to give a general guideline for fabricating functional separators compatible with post-lithium-ion batteries. The overall research trends and outlook for surface-functionalized separators are reviewed.

Bias Stress Stability of Solution-Processed Nano Indium Oxide Thin Film Transistor

In this paper, the effects of annealing temperature and other process parameters on spin-coated indium oxide thin film transistors (In₂O₃-TFTs) were studied. The research shows that plasma pretreatment of glass substrate can improve the hydrophilicity of glass substrate and stability of the spin-coating process. With Fourier transform infrared (FT-IR) and X-ray diffraction (XRD) analysis, it is found that In₂O₃ thin films prepared by the spin coating method are amorphous, and have little organic residue when the annealing temperature ranges from 200 to 300 °C. After optimizing process conditions with the spin-coated rotating speed of 4000 rpm and the annealing temperature of 275 °C, the performance of In₂O₃-TFTs is best (average mobility of 1.288 cm²·V⁻¹·s⁻¹, I_on/I_off of 5.93 × 10⁶, and SS of 0.84 V·dec⁻¹). Finally, the stability of In₂O₃-TFTs prepared at different annealing temperatures was analyzed by energy band theory, and we identified that the elimination of residual hydroxyl groups was the key influencing factor. Our results provide a useful reference for high-performance metal oxide semiconductor TFTs prepared by the solution method.

Functional separators towards the suppression of lithium dendrites for rechargeable high-energy batteries

Lithium metal battery (LMB) is considered to be one of the most promising electrochemical energy storage devices due to the high theoretical specific capacity and the lowest redox potential of metallic lithium; however, some key issues caused by lithium dendrites on the lithium metal anode seriously hinder its real-world applications. As an indispensable part of LMBs, the separator could serve as a physical barrier to prevent direct contact of the two electrodes and control ionic transport in batteries; it is an ideal platform for the suppression of lithium dendrites. In this review, the mechanism of lithium dendrite nucleation and growth are firstly discussed and then some advanced techniques are introduced for the precise characterization of lithium dendrites. On the basis of dendritic nucleation and growth principle, several feasible strategies are summarized for suppressing lithium dendrites by utilizing functional separators, including providing a mechanical barrier, promoting homogeneous lithium deposition, and regulating ionic transport. Finally, some challenges and prospects are proposed to clear the future development of functional separators. We anticipate that this paper will provide a new insight into the design and construction of functional separators for addressing the issues of lithium dendrites in high-energy batteries.

A Review of Functional Separators for Lithium Metal Battery Applications

Lithium metal batteries are considered “rough diamonds” in electrochemical energy storage systems. Li-metal anodes have the versatile advantages of high theoretical capacity, low density, and low reaction potential, making them feasible candidates for next-generation battery applications. However, unsolved problems, such as dendritic growths, high reactivity of Li-metal, low Coulombic efficiency, and safety hazards, still exist and hamper the improvement of cell performance and reliability. The use of functional separators is one of the technologies that can contribute to solving these problems. Recently, functional separators have been actively studied and developed. In this paper, we summarize trends in the research on separators and predict future prospects.

Highly Stable Porous Polyimide Sponge as a Separator for Lithium-metal Secondary Batteries

To inhibit Li-dendrite growth on lithium (Li)-metal electrodes, which causes capacity deterioration and safety issues in Li-ion batteries, we prepared a porous polyimide (PI) sponge using a solution-processable high internal-phase emulsion technique with a water-soluble PI precursor solution; the process is not only simple but also environmentally friendly. The prepared PI sponge was processed into porous PI separators and used for Li-metal electrodes. The physical properties (e.g., thermal stability, liquid electrolyte uptake, and ionic conductivity) of the porous PI separators and their effect on the Li-metal anodes (e.g., self-discharge and open-circuit voltage properties after storage, cycle performance, rate capability, and morphological changes) were investigated. Owing to the thermally stable properties of the PI polymer, the porous PI separators demonstrated no dimensional changes up to 180 °C. In comparison with commercialized polyethylene (PE) separators, the porous PI separators exhibited improved wetting ability for liquid electrolytes; thus, the latter improved not only the physical properties (e.g., improved the electrolyte uptake and ionic conductivity) but also the electrochemical properties of Li-metal electrodes (e.g., maintained stable self-discharge capacity and open-circuit voltage features after storage and improved the cycle performance and rate capability) in comparison with PE separators.

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

Secondary Li-ion batteries have been paid attention to wide-range applications of power source for the portable electronics, electric vehicle, and electric storage reservoir. Generally, lithium-ion batteries are comprised of four components including anode, cathode, electrolyte and separator. Although separators do not take part in the electrochemical reactions in a lithium-ion (Li-ion) battery, they conduct the critical functions of physically separating the positive and negative electrodes to prevent electrical short circuit while permitting the free flow of lithium ions through the liquid electrolyte that fill in their open porous structure. Hence, the separator is directly related to the safety and the power performance of the battery. Among a number of separators developed thus far, polyethylene (PE) and polypropylene (PP) porous membrane separators have been the most dominant ones for commercial Li-ion batteries over the decades because of their superior properties such as cost-efficiency, good mechanical strength and pore structure, electrochemical stability, and thermal shutdown properties. However, there are main issues for vehicular storage, such as nonpolarity, low surface energy and poor thermal stability, although the polyolefin separators have proven dependable in portable applications. Hence, in this review, we decide to provide an overview of the types of polyolefin microporous separators utilized in Li-ion batteries and the methods employed to modify their surface in detail. The remarkable results demonstrate that extraordinary properties can be exhibited by mono- and multilayer polyolefin separators if they are modified using suitable methods and materials.

A Review on Inorganic Nanoparticles Modified Composite Membranes for Lithium-Ion Batteries: Recent Progress and Prospects

Separators with high porosity, mechanical robustness, high ion conductivity, thin structure, excellent thermal stability, high electrolyte uptake and high retention capacity is today's burning research topic. These characteristics are not easily achieved by using single polymer separators. Inorganic nanoparticle use is one of the efforts to achieve these attributes and it has taken its place in recent research. The inorganic nanoparticles not only improve the physical characteristics of the separator but also keep it from dendrite problems, which enhance its shelf life. In this article, use of inorganic particles for lithium-ion battery membrane modification is discussed in detail and composite membranes with three main types including inorganic particle-coated composite membranes, inorganic particle-filled composite membranes and inorganic particle-filled non-woven mates are described. The possible advantages of inorganic particles application on membrane morphology, different techniques and modification methods for improving particle performance in the composite membrane, future prospects and better applications of ceramic nanoparticles and improvements in these composite membranes are also highlighted. In short, the contents of this review provide a fruitful source for further study and the development of new lithium-ion battery membranes with improved mechanical stability, chemical inertness and better electrochemical properties.

Adhesive Hybrid SiO2.01C0.23Hx Nanoparticulate Coating on Polyethylene (PE) Separator by Roll-to-Roll Atmospheric Pressure Plasma

For the ever-increasing demand for highly safe lithium-ion batteries (LIBs), the common sol-gel process provides heat-resistance to separators with an inorganic coating, where the adhesion to the separator is the key to safety and stability. In this paper, we present a SiO2.01C0.23Hx-coated polyethylene (PE) separator through a roll-to-roll atmospheric plasma-enhanced chemical vapor deposition (R2R-APECVD) of hexamethyldisiloxane (HMDSO)/Ar/O2. The adhesion strength of SiO2.01C0.23Hx-coated PE was tested by peel-off test and found to be higher than that of the commercial Al2O3-coated separator (0.28 N/mm vs. 0.06 N/mm). Furthermore, the SiO2.01C0.23Hx-coated PE separator showed better electrochemical performance in C-rate and long term cycle tests. FTIR, SEM, and XPS analysis indicate that the increased adhesion and electrochemical performance are attributed to the inner hybrid SiO2.01C0.23Hx coating with organic and inorganic components.

Graphene Oxide Induced Surface Modification for Functional Separators in Lithium Secondary Batteries

Functional separators, which have additional functions apart from the ionic conduction and electronic insulation of conventional separators, are highly in demand to realize the development of advanced lithium ion secondary batteries with high safety, high power density, and so on. Their fabrication is simply performed by additional deposition of diverse functional materials on conventional separators. However, the hydrophobic wetting nature of conventional separators induces the polarity-dependent wetting feature of slurries. Thus, an eco-friendly coating process of water-based slurry that is highly polar is hard to realize, which restricts the use of various functional materials dispersible in the polar solvent. This paper presents a surface modification of conventional separators that uses a solution-based coating of graphene oxide with a hydrophilic group. The simple method enables the large-scale tuning of surface wetting properties by altering the morphology and the surface polarity of conventional separators, without significant degradation of lithium ion transport. On the surface modified separator, superior wetting properties are realized and a functional separator, applicable to lithium metal secondary batteries, is demonstrated as an example. We believe that this simple surface modification using graphene oxide contributes to successful fabrication of various functional separators that are suitable for advanced secondary batteries.

Elucidating the Polymeric Binder Distribution within Lithium-Ion Battery Electrodes Using SAICAS

Polymeric binder distribution within electrodes is crucial to guarantee the electrochemical performance of lithium-ion batteries (LIBs) for their long-term use in applications such as electric vehicles and energy-storage systems. However, due to limited analytical tools, such analyses have not been conducted so far. Herein, the adhesion properties of LIB electrodes at different depths are measured using a surface and interfacial cutting analysis system (SAICAS). Moreover, two LiCoO₂ electrodes, dried at 130 and 230 °C, are carefully prepared and used to obtain the adhesion properties at every 10 μm of depth as well as the interface between the electrode composite and the current collector. At high drying temperatures, more of the polymeric binder material and conductive agent appears adjacent to the electrode surface, resulting in different adhesion properties as a function of depth. When the electrochemical properties are evaluated at different temperatures, the LiCoO₂ electrode dried at 130 °C shows a much better high-temperature cycling performance than does the electrode dried at 230 °C due to the uniform adhesion properties and the higher interfacial adhesion strength.

Comparative Study of the Adhesion Properties of Ceramic Composite Separators Using a Surface and Interfacial Cutting Analysis System for Lithium-Ion Batteries

Because of the constantly increasing demand for highly safe lithium-ion batteries (LIBs), interest in the development of ceramic composite separators (CCSs) is growing rapidly. Here, an in-depth study of the adhesion properties of the Al₂O₃ ceramic composite coating layer of CCSs is conducted using a peel test and a surface and interfacial cutting analysis system (SAICAS). Contrary to the 90 and 180° peel tests, which resulted in different adhesion strengths even for the same CCS sample, the SAICAS is able to measure the adhesion properties uniformly as a function of depth from the surface of the coating layer. The adhesion strengths measured at the midlayer (F _mid) and interface (F _inter, interlayer between the separator and the ceramic coating layer) are compared for various types of CCS samples with different amounts of polymeric binder, and it is found that F _inter is higher than F _mid for all CCSs. Compared with F _mid, F _inter is significantly affected by storage in the liquid electrolyte (under wet condition).

Effects of an Integrated Separator/Electrode Assembly on Enhanced Thermal Stability and Rate Capability of Lithium-Ion Batteries

To improve the rate capability and safety of lithium-ion batteries (LIBs), we developed an integrated separator/electrode by gluing polyethylene (PE) separators and electrodes using a polymeric adhesive (poly(vinylidene fluoride), PVdF). To fabricate thin and uniform polymer coating layers on the substrate, we applied the polymer solution using a spray-coating technique. PVdF was chosen because of its superior mechanical properties and stable electrochemical properties within the voltage range of commercial LIBs. The integrated separator/electrode showed superior thermal stability compared to that of the control PE separators. Although PVdF coating layers partially blocked the porous structures of the PE separators, resulting in reduced ionic conductivity (control PE = 0.666 mS cm^-1, PVdF-coated PE = 0.617 mS cm^-1), improved interfacial properties between the separators and the electrodes were obtained due to the intimate contact, and the rate capabilities of the LIBs based on integrated separators/electrodes showed 176.6% improvement at the 7 C rate (LIBs based on PVdF-coated and control PE maintained 48.4 and 27.4% of the initial discharge capacity, respectively).