Plasma activation and atomic layer deposition of TiO2 on polypropylene membranes for improved performances of lithium-ion batteries

Atomic layer deposition on flexible polymeric materials for lithium-ion batteries

Polymers have the distinctive qualities of being lightweight, flexible, and inexpensive and possessing good mechanical qualities. Consequently, these materials are employed in a wide range of applications, including lithium-ion batteries (LiBs). Interestingly, a variety of thin film materials can be deposited onto polymer substrates using the atomic layer deposition (ALD) technique. This is because the surface of many polymers has abundant reactive sites that are essential for the initial growth of ALD, such as functional hydroxyl -OH groups and -C[double bond, length as m-dash]O polar groups, aiding the smooth growth of ALD materials. Moreover, the diffusion growth mechanism, which is initiated by the nucleation and infiltration of precursors, can enable the initial growth of ALD materials even if the polymers lack these reactive polar groups. As polymers are composed of several chains, they have microporous characteristics, forming voids between the polymer chains. Because of these characteristics, polymers are considered ideal material substrates for investigating the promising future of the widely used ALD technique. The combination of polymer materials and the ALD method is becoming increasingly important in the advancements of high-performance LiBs. This review focuses on the present understanding of the role of polymer materials in the ALD technique for the fabrication of lithium-ion batteries.

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.

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.

A high performance composite separator with robust environmental stability for dendrite-free lithium metal batteries

The garnet ceramic Li_6.4La₃Zr_1.4Ta_0.6O₁₂ (LLZTO) modified separators have been proposed to overcome the poor thermal stability and wettability of commercial polyolefin separators. However, the side reaction of LLZTO in the air leads to deterioration of environmental stability of composite separators (PP-LLZTO), which will limit the electrochemical performance of batteries. Herein, the LLZTO with the polydopamine (PDA) coating (LLZTO@PDA) was prepared by solution oxidation, and then applied it to a commercial polyolefin separator to achieve a composite separator (PP-LLZTO@PDA). LLZTO@PDA is stable in the air, and no Li₂CO₃ can be observed on the surface even after 90 days in the air. Besides, LLZTO@PDA coating endows the PP-LLZTO@PDA separator with the tensile strength (up to 103 MPa), good wettability (contact angle 0°) and high ionic conductivity (0.93 mS cm^-1). Consequently, the Li/PP-LLZTO@PDA/Li symmetric cell cycles stably for 600 h without significant dendrites generation, and the assembled Li//LFP cells with PP-LLZTO@PDA-D30 separators deliver a high capacity retention of 91.8% after 200 cycles at 0.1C. This research provides a practical strategy for constructing composite separators with excellent environmental stability and high electrochemical properties.

Ultrathin ALD Aluminum Oxide Thin Films Suppress the Thermal Shrinkage of Battery Separator Membranes

Thermal runaway is a major safety concern in the applications of Li-ion batteries, especially in the electric vehicle (EV) market. A key component to mitigate this risk is the separator membrane, a porous polymer film that prevents physical contact between the electrodes. Traditional polyolefin-based separators display significant thermal shrinkage (TS) above 100 °C, which increases the risk of battery failure; hence, suppressing the TS up to 180 °C is critical to enhancing the cell's safety. In this article, we deposited thin-film coatings (less than 10 nm) of aluminum oxide by atomic layer deposition (ALD) on three different types of separator membranes. The deposition conditions and the plasma pretreatment were optimized to decrease the number of ALD cycles necessary to suppress TS without hindering the battery performance for all of the studied separators. A dependency on the separator composition and porosity was found. After 100 ALD cycles, the thermal shrinkage of a 15 μm thick polyethylene membrane with 50% porosity was measured to be below 1% at 180 °C, with ionic conductivity >1 mS/cm. Full battery cycling with NMC532 cathodes demonstrates no hindrance to the battery's rate capability or the capacity retention rate compared to that of bare membranes during the first 100 cycles. These results display the potential of separators functionalized by ALD to enhance battery safety and improve battery performance without increasing the separator thickness and hence preserving excellent volumetric energy.

Recent Development in Composite Membranes for Flow Batteries

Flow batteries (FBs) are one of the most attractive candidates for stationary energy storage and vital in realizing the wide application of renewable energies. Membranes play an important role in isolating redox couples while transporting ions to close the internal electrical circuit. Therefore, membranes with high selectivity and conductivity are highly important. Among different membranes, a composite membrane with independent design of support layer and thin selective top layer becomes one of the most promising candidates to break the trade-off between selectivity and conductivity. In this Review, recent studies on composite membranes for FBs and the principles of membrane design in different systems are discussed and summarized. Finally, the future direction on membrane design for different FBs is presented, which will provide an extensive, comprehensive reference to design and construct high-performance composite membranes for FBs.

Building Safe Lithium-Ion Batteries for Electric Vehicles: A Review

Abstract

Lithium-ion batteries (LIBs), with relatively high energy density and power density, have been considered as a vital energy source in our daily life, especially in electric vehicles. However, energy density and safety related to thermal runaways are the main concerns for their further applications. In order to deeply understand the development of high energy density and safe LIBs, we comprehensively review the safety features of LIBs and the failure mechanisms of cathodes, anodes, separators and electrolyte. The corresponding solutions for designing safer components are systematically proposed. Additionally, the in situ or operando techniques, such as microscopy and spectrum analysis, the fiber Bragg grating sensor and the gas sensor, are summarized to monitor the internal conditions of LIBs in real time. The main purpose of this review is to provide some general guidelines for the design of safe and high energy density batteries from the views of both material and cell levels.

Graphic Abstract

Safety of lithium-ion batteries (LIBs) with high energy density becomes more and more important in the future for EVs development. The safety issues of the LIBs are complicated, related to both materials and the cell level. To ensure the safety of LIBs, in-depth understanding of the safety features, precise design of the battery materials and real-time monitoring/detection of the cells should be systematically considered. Here, we specifically summarize the safety features of the LIBs from the aspects of their voltage and temperature tolerance, the failure mechanism of the LIB materials and corresponding improved methods. We further review the in situ or operando techniques to real-time monitor the internal conditions of LIBs.

Water-Dispersed Poly(p-Phenylene Terephthamide) Boosting Nano-Al2O3-Coated Polyethylene Separator with Enhanced Thermal Stability and Ion Diffusion for Lithium-Ion Batteries

Polyethylene (PE) membranes coated with nano-Al2O3 have been improved with water-dispersed poly(p-phenylene terephthamide) (PPTA). From the scanning electron microscope (SEM) images, it can be seen that a layer with a honeycombed porous structure is formed on the membrane. The thus-formed composite separator imbibed with the electrolyte solution has an ionic conductivity of 0.474 mS/cm with an electrolyte uptake of 335%. At 175 °C, the assembled battery from the synthesized composite separator explodes at 3200 s, which is five times longer than the battery assembled from an Al2O3-coated polyethylene (PE) membrane. The open circuit voltage of the assembled battery using a composite separator drops to zero at 600 s at an operating temperature of 185 °C, while the explosion of the battery with Al2O3-coated PE occurs at 250 s. More importantly, the interface resistance of the cell assembled from the composite separator decreases to 65 Ω. Hence, as the discharge rate increases from 0.2 to 1.0 C, the discharge capacity of the battery using composite separator retains 93.5%. Under 0.5 C, the discharge capacity retention remains 99.4% of its initial discharge capacity after 50 charge-discharge cycles. The results described here demonstrate that Al2O3/PPTA-coated polyethylene membranes have superior thermal stability and ion diffusion.

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.

Asymmetrically coated LAGP/PP/PVDF–HFP composite separator film and its effect on the improvement of NCM battery performance

Li_1.5Al_0.5Ge_1.5(PO₄)₃ (LAGP) is an inorganic solid electrolyte with a Na superionic conductor (NASICON) structure that provides a channel for lithium ion transport. We coated LAGP particles on one side of a polypropylene (PP) separator film to improve the ionic conductivity of the separator, and water-dispersed polyvinylidene fluoride–hexafluoropropylene (PVDF–HFP) on the other side to reduce the interfacial resistance between the separator and the lithium metal anode. The results show that the LAGP/PP/PVDF–HFP separator has a high ionic conductivity (1.06 mS cm⁻¹) at room temperature (PP separator: 0.70 mS cm⁻¹), and an electrochemical window of 5.2 V (vs. Li⁺/Li). The capacity retention of a NCM|LAGP/PP/PVDF–HFP|graphite full cell is 81.0% after 300 charge–discharge cycles at 0.2C. When used in a NCM|LAGP/PP/PVDF–HFP|Li half-cell system, the initial discharge capacity is 172.5 mA h g⁻¹ at 0.2C, and the capacity retention is 83.2% after 300 cycles. More significantly, the surface of the Li anode is smooth and flat after 200 cycles. The interface resistance increased from 7 to 109 Ω after 100 cycles at 0.2C. This indicates that the synergistic effect of the asymmetric coated LAGP and PVDF–HFP is beneficial to inhibiting the growth of lithium dendrites in the battery and reduces the interface resistance.

A LAGP/PP/PVDF–HFP double-sided asymmetric composite separator film was prepared to improve the battery performance in LIBs.

Atomic layer deposition for membrane interface engineering

In many applications, interfaces govern the performance of membranes. Structure, chemistry, electrostatics, and other properties of interfaces can dominate the selectivity, flux, fouling resistance, and other critical aspects of membrane functionality. Control over membrane interfacial properties, therefore, is a powerful means of tailoring performance. In this Minireview, we discuss the application of atomic layer deposition (ALD) and related techniques in the design of novel membrane interfaces. We discuss recent literature in which ALD is used to (1) modify the surface chemistry and interfacial properties of membranes, (2) tailor the pore sizes and separation characteristics of membranes, and (3) enable novel advanced functional membranes.

Elucidation of Titanium Dioxide Nucleation and Growth on a Polydopamine-Modified Nanoporous Polyvinylidene Fluoride Substrate via Low-Temperature Atomic Layer Deposition

Interfaces combining polydopamine (PDA) and nanoparticles have been widely utilized for fabricating hybrid colloidal particles, thin films, and membranes for applications spanning biosensing, drug delivery, heavy metal detection, antifouling membranes, and lithium ion batteries. However, fundamental understanding of the interaction between PDA and nanoparticles is still limited, especially the impact of PDA on nanoparticle nucleation and growth. In this work, PDA is used to generate functional bonding sites for depositing titanium dioxide (TiO₂) via atomic layer deposition (ALD) onto a nanoporous polymer substrate for a range of ALD cycles (<100). The resulting hybrid membranes are systematically characterized using water contact angle, scanning electron microscopy, atomic force microscopy, nitrogen adsorption and desorption, and X-ray photoelectron spectroscopy (XPS). An intriguing nonlinear relationship was observed between the number of ALD cycles and changes in surface properties (water contact angle and surface roughness). Together with XPS study, those changes in surface properties were exploited to probe the nanoparticle nucleation and growth process on complex PDA-coated porous polymer substrates. Molecular level understanding of inorganic and polymer material interfaces will shed light on fine-tuning nanoparticle-modified polymeric membrane materials.

Crude-Oil-Repellent Membranes by Atomic Layer Deposition: Oxide Interface Engineering

Crude oil fouling on membrane surfaces is a persistent, crippling challenge in oil spill remediation and oilfield wastewater treatment. In this research, we present how a nanosized oxide coating can profoundly affect the anti-crude-oil property of membrane materials. Select oxide coatings with a thickness of ∼10 nm are deposited conformally on common polymer membrane surfaces by atomic layer deposition to significantly mitigate fouling during filtration processes. TiO₂- and SnO₂-coated membranes exhibited far greater anti-crude-oil performance than ZnO- and Al₂O₃-coated ones. Tightly bound hydration layers play a crucial role in protecting the surface from crude oil adhesion, as revealed by molecular dynamics simulations. This work provides a facile strategy to fabricate crude-oil-resistant membranes with negligible impact on membrane structure, and also demonstrates that, contrary to common belief, excellent crude oil resistance can be achieved easily without implementation of sophisticated, hierarchical structures.

Novel Ceramic-Grafted Separator with Highly Thermal Stability for Safe Lithium-Ion Batteries

The separator is a critical component of lithium-ion batteries (LIBs), which not only allows ionic transport while it prevents electrical contact between electrodes but also plays a key role for thermal safety performance of LIBs. However, commercial separators for LIBs are typically microporous polyolefin membranes that pose challenges for battery safety, due to shrinking and melting at elevated temperature. Here, we demonstrate a strategy to improve the thermal stability and electrolyte affinity of polyethylene (PE) separators. By simply grafting the vinylsilane coupling reagent on the surface of the PE separator by electron beam irradiation method and subsequent hydrolysis reaction into the Al³⁺ solution, an ultrathin Al₂O₃ layer is grafted on the surface of the porous polymer microframework without sacrificing the porous structure and increasing the thickness. The as-synthesized Al₂O₃ ceramic-grafted separator (Al₂O₃-CGS) shows almost no shrinkage at 150 °C and decreases the contact angle of the conventional electrolyte compared with the bare PE separator. Notably, the full cells with the Al₂O₃-CGSs exhibit better cycling performance and rate capability and also provide stable open circuit voltage even at 170 °C, indicating its promising application in LIBs with high safety and energy density.

Advances in preparation, modification, and application of polypropylene membrane

Polypropylene (PP) is one of the most used polymers for microporous membrane fabrication due to its good thermal stability, chemical resistance, mechanical strength, and low cost. There have been numerous studies reporting the developments and applications of PP membranes. However, PP membrane with high performance is still a challenge. Thus, this article presents a comprehensive overview of the advances in the preparation, modification and application of PP membrane. The preparation methods of PP membrane are firstly reviewed, followed by the modification approaches of PP membrane. The modifications includes hydrophilic and superhydrophobic modification so that the PP membranes become more suitable to be applied either in aqueous applications or in non-aqueous ones. The fouling resistant of hydrophilized PP membrane and the wetting resistant of superhydrophobized PP membrane are then reviewed. Finally, special attention is given to the various potential applications and industrial outlook of the PP membranes.

Tannic-Acid-Coated Polypropylene Membrane as a Separator for Lithium-Ion Batteries

To solve the wetting capability issue of commercial polypropylene (PP) separators in lithium-ion batteries (LIBs), we developed a simple dipping surface-coating process based on tannic acid (TA), a natural plant polyphenol. Fourier transform infrared and X-ray photoelectron measurements indicate that the TA is coated successfully on the PP separators. Scanning electron microscopy images show that the TA coating does not destroy the microporous structure of the separators. After being coated with TA, the PP separators become more hydrophilic, which not only enhances the liquid electrolyte retention ability but also increases the ionic conductivity. The battery performance, especially for power capability, is improved after being coated with TA. It indicates that this TA-coating method provides a promising process by which to develop an advanced polymer membrane separator for lithium-ion batteries.

Magnetron sputtering deposition of TiO2 particles on polypropylene separators for lithium-ion batteries

After MSD of TiO₂, the modified separators presented suppressed thermal shrinkage and improved wettability to electrolytes, resulting in better cell performances.

High hydrophilicity and excellent adsorption ability of a stretched polypropylene/graphene oxide composite membrane achieved by plasma assisted surface modification

Through a plasma treatment, a PP-based composite membrane with a high hydrophilicity and an excellent adsorption ability was developed.