Surface-modified polyethylene separator via oxygen plasma treatment for lithium ion battery

Advanced Poly (Ether Ether Ketone) Separator for Lithium Metal Battery

The development of high-performance separators is urgently needed to improve the safety and electrochemical performance of high-energy-density lithium metal batteries (LMB). Poly (ether ether ketone) (PEEK) is an ideal separator candidate due to its high chemical resistance and excellent thermal stability. However, the processing of PEEK for separators with proper porous structure is rather challenging. Beyond the conventional sulfonation process of PEEK, here, a reversible chemical modification strategy is exploited to fabricate heat-resistant PEEK separators with sophisticated hierarchical pore architecture. The lyophilic PEEK separators including dense surface layers, middle layers with horizontally aligned pore arrays, and honeycomb-structured bottom layers enable fast ion transport and uniform Li+ flux, realizing dendrite-free characteristics during the lithium deposition process. Hence, the PEEK separator assembled LiFePO4||Li battery delivers a remarkable capacity of 103.6 mAh·g-1 after 1000 cycles at 3 C, and offers more than two times longer cycle life than that of other PEEK-based separators. Even at 70 °C, a high capacity retention rate of 84.2% is achieved after 200 cycles, ensuring battery safety in high-temperature environments. Different from the commonly used surface modification strategy for functional separators, the approach reported herein exhibits a fundamental advance in separator manufacturing for future high-safety LMBs.

Functionalized Separators Boosting Electrochemical Performances for Lithium Batteries

The growing demands for energy storage systems, electric vehicles, and portable electronics have significantly pushed forward the need for safe and reliable lithium batteries. It is essential to design functional separators with improved mechanical and electrochemical characteristics. This review covers the improved mechanical and electrochemical performances as well as the advancements made in the design of separators utilizing a variety of techniques. In terms of electrolyte wettability and adhesion of the coating materials, we provide an overview of the current status of research on coated separators, in situ modified separators, and grafting modified separators, and elaborate additional performance parameters of interest. The characteristics of inorganics coated separators, organic framework coated separators and inorganic-organic coated separators from different fabrication methods are compared. Future directions regarding new modified materials, manufacturing process, quantitative analysis of adhesion and so on are proposed toward next-generation advanced lithium batteries.

Advanced Separator Materials for Enhanced Electrochemical Performance of Lithium-Sulfur Batteries: Progress and Prospects

Lithium-sulfur (Li-S) batteries are promising energy storage devices owing to their high theoretical specific capacity and energy density. However, several challenges, including volume expansion, slow reaction kinetics, polysulfide shuttle effect and lithium dendrite formation, hinder their commercialization. Separators are a key component of Li-S batteries. Traditional separators, made of polypropylene and polyethylene, have certain limitations that should be addressed. Therefore, this review discusses the basic properties and mechanisms of Li-S battery separators, focuses on preparing different functionalized separators to mitigate the shuttle effect of polysulfides. This review also introduces future research trends, emphasizing the potential of separator functionalization in advancing the Li-S battery technology.

Applications of Plasma Technologies in Recycling Processes

Plasmas are reactive ionised gases, which enable the creation of unique reaction fields. This allows plasmas to be widely used for a variety of chemical processes for materials, recycling among others. Because of the increase in urgency to find more sustainable methods of waste management, plasmas have been enthusiastically applied to recycling processes. This review presents recent developments of plasma technologies for recycling linked to economical models of circular economy and waste management hierarchies, exemplifying the thermal decomposition of organic components or substances, the recovery of inorganic materials like metals, the treatment of paper, wind turbine waste, and electronic waste. It is discovered that thermal plasmas are most applicable to thermal processes, whereas nonthermal plasmas are often applied in different contexts which utilise their chemical selectivity. Most applications of plasmas in recycling are successful, but there is room for advancements in applications. Additionally, further perspectives are discussed.

Fluorine Chemistry in Rechargeable Batteries: Challenges, Progress, and Perspectives

The renewable energy industry demands rechargeable batteries that can be manufactured at low cost using abundant resources while offering high energy density, good safety, wide operating temperature windows, and long lifespans. Utilizing fluorine chemistry to redesign battery configurations/components is considered a critical strategy to fulfill these requirements due to the natural abundance, robust bond strength, and extraordinary electronegativity of fluorine and the high free energy of fluoride formation, which enables the fluorinated components with cost effectiveness, nonflammability, and intrinsic stability. In particular, fluorinated materials and electrode|electrolyte interphases have been demonstrated to significantly affect reaction reversibility/kinetics, safety, and temperature tolerance of rechargeable batteries. However, the underlining principles governing material design and the mechanistic insights of interphases at the atomic level have been largely overlooked. This review covers a wide range of topics from the exploration of fluorine-containing electrodes, fluorinated electrolyte constituents, and other fluorinated battery components for metal-ion shuttle batteries to constructing fluoride-ion batteries, dual-ion batteries, and other new chemistries. In doing so, this review aims to provide a comprehensive understanding of the structure-property interactions, the features of fluorinated interphases, and cutting-edge techniques for elucidating the role of fluorine chemistry in rechargeable batteries. Further, we present current challenges and promising strategies for employing fluorine chemistry, aiming to advance the electrochemical performance, wide temperature operation, and safety attributes of rechargeable batteries.

Facile Enhancement of Electrochemical Performance of Solid-State Supercapacitor via Atmospheric Plasma Treatment on PVA-Based Gel-Polymer Electrolyte

A facile oxygen (O₂) atmospheric plasma treatment is applied to a polyvinyl alcohol (PVA) matrix to enhance its wettability and hydrophilicity. The optimal plasma treatment conditions are determined by varying the applied plasma power and plasma treatment time. A PVA matrix treated with a plasma power of 120 W for 5 s shows the most hydrophilicity owing to successful formation of carbonyl (-CO, >C=O) functional groups without any structural degradation. The plasma-treated PVA matrix is used as the gel-polymer electrolyte of a solid-state supercapacitor (SSC) by immersing solid matrix into various liquid electrolytes, such as sodium sulfate (Na₂SO₄), sulfuric acid (H₂SO₄), and potassium hydroxide (KOH). Compared with the pristine PVA-based device, PVA-120W5/Na₂SO₄-, PVA-120W5/H₂SO₄-, and PVA-120W5/KOH-based SSCs show 2.03, 2.05, and 2.14 times higher specific capacitances, respectively. The plasma-treated PVA matrix shows increased specific capacitance owing to the increased wettability, which in turn increases the ion transportation and reduces the electrical resistance. This study successfully demonstrates that the electrochemical performance of a SSC can be readily enhanced through plasma treatment for a short time (≤5 s).

"Polymer-in-Ceramic" Membrane for Thermally Safe Separator Applications

In this work, a facile casting method was utilized to prepare "polymer-in-ceramic" microporous membranes for thermally safe battery separator applications; that is, a series of composite membranes composed of silicon dioxide (SiO₂) as a matrix and polyvinylidene fluoride (PVDF) as a binder were prepared. The effects of different SiO₂ contents on various physical properties of membranes such as the porosity, electrolyte absorption rate, electrochemical stability, and especially thermal stability of the SiO₂/PVDF composite membranes were systematically studied. Compared with a commercial polypropylene separator, the SiO₂/PVDF membrane has a higher porosity (66.0%), electrolyte absorption (239%), and ion conductivity (1.0 mS·cm^-1) and superior thermal stability (only 2.1% shrinkage at 200 °C for 2 h) and flame retardancy. When the content of SiO₂ in the membrane reached 60% (i.e., PS6), LiFePO₄/PS6/Li half-cells exhibited excellent cycle stability (138.2 mA h·g^-1 discharging capacity after 100 cycles at 1C) and Coulombic efficiency (99.1%). The above advantages coupled with the potential for rapid and large-scale production reveal that the "polymer-in-ceramic" SiO₂/PVDF membrane has prospective separator applications in secondary lithium-ion batteries.

Polyethylene separator supported thin-film composite forward osmosis membranes for concentrating lithium enriched brine

To extract lithium from salt lake brine involves a process of separation and concentration. After separating lithium from brine, the lithium ion concentration is generally a few hundred mg/L which is far below the required 20-30 g/L (as Li⁺) before precipitation as lithium carbonate. The concentration step of a lithium enriched brine is crucial but highly energy-intensive. Spontaneous forward osmosis (FO) technology offers the possibility for concentrating lithium ions with low energy. Because the concentrating process involves both feed and draw solution with very high salinity, it is highly desirable to have a high performance FO membrane with a low structural parameter as well as a high rejection to ions. In this work, thin polyethylene separator supported FO (PE-FO) membranes were prepared and post-treated stepwise with benzyl alcohol (BA) and hydraulic compaction. The effect of the post-treatment on the FO performance was systematically analyzed. Excellent FO performance was achieved: the water flux and reverse salt flux selectivity were 66.3 LMH and 5.25 L/g, respectively, when the active layer is oriented towards the 0.5 M NaCl draw solution with deionized water as the feed. To the best of our knowledge, this FO flux is the highest ever reported in the open literature under similar test conditions. Applied in concentrating lithium enriched brine, the membrane showed superior water flux using saturated MgCl₂ as draw solution. A new FO model was established to simulate the water flux during the concentration process with good agreement with the experimental results. The promising results using PE-FO membrane for lithium enrichment opens a new frontier for the potential application of FO membranes.

Ultrastable Interfacial Contacts Enabling Unimpeded Charge Transfer and Ion Diffusion in Flexible Lithium-Ion Batteries

Deteriorating interfacial contact under mechanical deformation induces large cracks and high charge transfer resistance, resulting in a severe capacity fading of flexible lithium-ion batteries (LIBs). Herein, an oxygen plasma treatment on a polymer separator combined with high-speed centrifugal spraying to construct ultrastable interfacial contacts is reported. With the treatment, abundant hydrophilic oxygen-containing functional groups are produced and ensure strong chemical adhesion between the separator and the active materials. With single walled carbon nanotubes (SWCNTs) sprayed onto the active materials, a dense thin film is formed as the current collector. Meanwhile, the centrifugal force caused by high-speed rotation together with van der Waals forces under fast evaporation produces a much closer interface between the current collector and the active materials. As a result of this ultrastable interfacial interaction, the integrated electrode shows no structural failure after 5000 bending cycles with the charge-transfer resistance as low as 35.8% and a Li-ion diffusion coefficient nearly 19 times of the untreated electrode. Flexible LIBs assembled with these integrated electrodes show excellent structural and electrochemical stability, and can work steadily under various deformed states and repeated bending. This work provides a new technique toward rational design of electrode configuration for flexible LIBs.

Experimental Studies on the Influence of Plasma Treatment of Polyethylene in Carbon Fiber Composites: Mechanical and Morphological Studies

This research focused on enhancement of mechanical properties in carbon fiber (CF)-filler-reinforced linear low-density polyethylene (PE) matrix composites. A hand layup method using an oven was used as the fabrication method. Improvement in adhesion was achieved by oxygen plasma treatment to the PE matrix. CF and PE were initially mixed by normal stirring, ultrasonication and mechanical stirring before being filtered and dried for fabrication. Better tensile results were observed with a plasma-treated polyethylene (PEP)/10 wt.% CF combination, with a maximum tensile strength of 21.5 MPa and improvement in the properties of up to 12.57% compared to non-plasma PE with the same CF addition. The addition of carbon fibers at 13 and 15 wt.% resulted in a reduction in the tensile strength properties to 18.2 MPa and 17.7 MPa, respectively. This reduction in tensile strength was due to agglomeration of CF with plasma- and non-plasma-treated PE. The fabrication condition of 180 °C temperature for 20 min showed better tensile properties than other conditions. The SEM results following tensile testing revealed enhanced CF filler adherence with plasma PE results, as well as fewer surface deformations. A higher flexural strength of 25.87 MPa was observed for the plasma treated PE/7 wt.% CF combination.

Prussian Blue Nanolayer-Embedded Separator for Selective Segregation of Nickel Dissolution in High Nickel Cathodes

Transition metal layered oxides (LiNi_xCo_yMn_1-x-yO₂, NCM) have been considered as one of the most promising cathodes for lithium-ion batteries used in long-mileage electric vehicles and energy storage systems. Despite its potential interest, dissolved transition metal (TM) ions toward anode sides can catalyze parasitic reactions such as electrolytic decomposition and dendritic Li growth, ultimately leading to catastrophic safety hazards. In this study, we demonstrate that Prussian Blue (PB) nanoparticles anchored to a commercial PE separator significantly reduce cell resistance and effectively suppress TM crossover during cycling, even under harsh conditions that accelerate Ni dissolution. Therefore, using a PB-coated separator in a harsh condition to intentionally dissolve Ni²⁺ ions at a high cutoff potential of 4.6 V, NCM||graphite full cells maintain 50.8% of their initial capacity at the 150th cycle. Scalable production of PB-coated separator through the facile synthetic methods can help establish a new research direction for the design of high-energy-density batteries.

Wettability and Adhesion of Polyethylene Powder Treated with Non-Equilibrium Various Gaseous Plasma in Semi-Industrial Equipment

Plasma treatment of polyethylene powder was carried out in low-pressure gaseous plasma sustained in a semi-industrial reactor powered with a microwave source, in which it was specifically worked with the residual atmosphere. Timed applications of plasma-treated powder in air atmosphere were carried out to study their influence on the adhesion. Based on wettability and adhesion, a treatment time of 5 min was selected for the study of other working gases (nitrogen, oxygen, hydrogen, argon and a mixture of nitrogen and hydrogen). The measurements of wettability showed the highest adhesion increase for nitrogen. The highest increase of adhesion and of surface oxygen contain shown by oxygen treatment. By contrast, treatment with hydrogen resulted in increased roughness of the sintered surface of the powder. The selection of appropriate working gases which are not standard in industrial processes enables one to atypically regulate the adhesion or wettability.

Ionic Covalent Organic Frameworks for Energy Devices

Covalent organic frameworks (COFs) are a class of porous crystalline materials whose facile preparation, functionality, and modularity have led to their becoming powerful platforms for the development of molecular devices in many fields of (bio)engineering, such as energy storage, environmental remediation, drug delivery, and catalysis. In particular, ionic COFs (iCOFs) are highly useful for constructing energy devices, as their ionic functional groups can transport ions efficiently, and the nonlabile and highly ordered all-covalent pore structures of their backbones provide ideal pathways for long-term ionic transport under harsh electrochemical conditions. Here, current research progress on the use of iCOFs for energy devices, specifically lithium-based batteries and fuel cells, is reviewed in terms of iCOF backbone-design strategies, synthetic approaches, properties, engineering techniques, and applications. iCOFs are categorized as anionic COFs or cationic COFs, and how each of these types of iCOFs transport lithium ions, protons, or hydroxides is illustrated. Finally, the current challenges to and future opportunities for the utilization of iCOFs in energy devices are described. This review will therefore serve as a useful reference on state-of-the-art iCOF design and application strategies focusing on energy devices.

Preparation of a superhydrophilic SiO2 nanoparticles coated chitosan-sodium phytate film by a simple ethanol soaking process

The development of environmentally friendly and transparent superhydrophilic food packaging materials is essential in our daily lives. The objective of this study was to develop a simple method of preparing a superhydrophilic, transparent, and biodegradable composite film. The composite film was obtained by soaking a chitosan-sodium phytate film in an ethanol solution of SiO₂ nanoparticles. The results showed that when the chitosan-sodium phytate film was coated with SiO₂ nanoparticles that were dissolved in 75% ethanol, its water contact angle (WCA) was reduced from 100° to 3°, and the film surface was changed from a hydrophobic to a superhydrophilic. Furthermore, the oxygen transmission rate (OTR) was significantly reduced, and the mechanical properties of the film were improved. The method is easy to carry out and can be used for the potential production of superhydrophilic materials.

New Method for Optimization of Polymer Powder Plasma Treatment for Composite Materials

This paper describes a newly developed testing method for determination of the adhesivity of a film sintered from thermoplastic powder. This method is based on the modified EN 15337 standard. Application of this method enables an effective development of thermoplastic composites with enhanced adhesion between reinforcement and matrix and/or high-quality joints between plastics and dissimilar materials. The proposed method was successfully tested on a series of polyethylene powders treated in the oxygen atmosphere for 0–1200 s. Adhesion to metal and glass substrates in dependence on treatment conditions is described along with powder wettability and X-ray photoelectron spectroscopy analysis. The results show an increase in adhesion to metal by 580% and to glass by 1670% for the longest treatment time, compared to a nontreated powder. Sintering of treated powders revealed a strong influence of treatment time on the melting process. The XPS analysis confirmed the formation of new oxygen groups (C–O, C=O, O–C=O). The method reveals a specific behavior of powders based on treatment conditions, which is crucial for the optimization of plasma treatment for the improved adhesion, applicability of polymer powders, and a development of composite materials.

Improved Adhesion of Nafion™-Coated Separator to Water-Processable LiNi0.5Mn1.5O4 Electrodes

The adhesion between electrode and separator is a key feature in cell assembly. Nafion™-coated separators for water-processed LiNi0.5Mn1.5O4 (LNMO) electrodes are here proposed as an alternative to the polyolefin separators. Specifically, polyolefin separators are modified with Nafion™ solutions and their adhesion to high-potential LNMO electrodes is investigated. The physicochemical properties of the Nafion™-coated separator and its electrochemical performance in Li/LNMO cells are discussed and compared to those obtained with polyolefin Celgard® (Charlotte, NC, USA) PP2075 separator. Improved adhesion and cycling stability, which could be further enhanced by a mild lamination process, were demonstrated with a thin layer of Nafion™ (0.1 mg cm−2).

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.

Plasma treated TiO2/C nanofibers as high performance anode materials for sodium-ion batteries

TiO₂ has been a promising anode material for sodium-ion batteries because it is low-cost and environment-friendly. However, its electrochemical performance at high rates is still not acceptable. Herein, we synthesized a TiO₂/C nanofiber material by the electrospinning method, and introduced air plasma treatments to modify the obtained material. Characterization results indicate that after the plasma treatments, the C fibers may have reacted with the plasma, and the surface areas of the nanofibers are increased. Electrochemical tests show this plasma treatment may be beneficial to the rate performance. The TiO₂/C nanofiber with plasma treatment could deliver a high redox capacity of 191 mA h g⁻¹ after 500 cycles at a very high rate of 10C (3300 mA g⁻¹). The superior effects of the plasma treatment on the rate performance may provide new insights for developing better materials for practical sodium-ion batteries.

Plasma treatment greatly improves the rate capability of TiO₂/C nanofibers.

Polyethylene Battery Separator as a Porous Support for Thin Film Composite Organic Solvent Nanofiltration Membranes

Organic solvent nanofiltration (OSN) has made significant advances recently, and it is now possible to fabricate thin film composite (TFC) membranes with a selective layer thickness below 10 nm that gives ultrafast solvent permeance. However, such high permeance is inadvertently limited by the support membrane beneath the selective layer, and thus there is an urgent need to develop a suitable support to maximize TFC performance. In this work, we employed a commercially available polyethylene (PE) battery separator as a porous support to fabricate high performance TFC OSN membranes. To deposit a uniform polyamide selective layer onto the porous support via interfacial polymerization, the PE support was hydrophilized with O₂ plasma and the reaction efficiency was optimized using a surfactant. Owing to the high surface porosity of the PE support and the high permselectivity of the PA layer, the PE-supported TFC membrane outperformed the previously reported OSN membranes and its performance exceeded the current performance upper bound. A solvent activation step dramatically improved the solvent permeance by 5-fold while maintaining nanoseparation properties. In addition to the superior OSN performance, the commercial availability of the PE support and simplified TFC fabrication protocol would make the PE-supported OSN membranes commercially attractive.