A thin inorganic composite separator for lithium-ion batteries

High-performance cellulose aerogel membrane for lithium-ion battery separator

Lithium-ion batteries (LIBs) are the mainstream of the energy storage device market. Efficient and environmentally friendly separators are beneficial for LIBs. Here, we prepared a regenerated cellulose (RC) aerogel with three-dimensional (3D) pores, which was used as the separators of LIBs. Under the effects of homogeneous pore structure and excellent specific surface area, LIBs that use 3 wt% RC aerogel membrane as a separator showed the initial specific capacity of 101.3 mAh g-1 at 1C, 74.3 % capacity retention rate after 110 cycles, which were higher than that of the commercial Celgard 2340 separator-based battery. In addition, the stability and wettability of the RC aerogel membranes as separators were also studied. These results indicated that the RC aerogel membranes can be used as efficient and environmentally friendly cellulose-based separators for LIBs.

Unveiling the potential of emergent nanoscale composite polymer electrolytes for safe and efficient all solid-state lithium-ion batteries

Solid-state polymer electrolytes (SSPEs) are promising materials for Li-ion batteries due to their enhanced safety features, which are crucial for preventing short circuits and explosions, replacing traditional liquid electrolytes with solid electrolytes are increasingly important to improve battery reliability and lifespan. There are essentially three-types of solid-state electrolytes such as solid polymer electrolyte, composite based polymer electrolyte and gel-based polymer electrolyte are largely used in battery applications. Additionally, battery separators must have high ionic conductivity and porosity to boost safety and performance. Durable solid composites electrolytes with excellent thermal and mechanical properties are key to reducing the risk of lithium dendrite growth, thereby improving overall battery efficiency. Despite their potential, challenges like scalability, cost and real-world performance optimizations still need to be addressed.

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.

Graphic Abstract

Sequential Deposition of Integrated Cathode-Inorganic Separator-Anode Multilayers for High Performance Li-Ion Batteries

A porous, spray-deposited Al₂O₃-based separator was developed to enable the direct deposition of an electrode/separator/electrode Li-ion battery full cell assembly in a single operation. The optimized sprayed separator consisted of 50 nm Al₂O₃ particles, 1 wt % poly(acrylic acid), and 5 wt % styrene-butadiene rubber, deposited from an 80:20 vol % suspension of water and isopropanol. Separators between 5 and 22 μm thick had consistent and similar porosity of ∼58%, excellent wettability, thermal stability to at least 180 °C, adequate electrochemical stability and high effective ionic conductivity of ∼1 mS cm^-1 at room temperature in an EC/DMC electrolyte, roughly double that of a conventional polypropylene separator. A sequentially deposited three-layer LiFePO₄/Al₂O₃/Li₄Ti₅O₁₂ full cell, the first of its kind, showed similar rate performance to an identical cell with a conventional polypropylene separator, with a capacity of ∼50 mAh g^-1 at 30 C. However, after cycling at 2 C for 400 cycles, Al₂O₃ separator full cells retained 96.3% capacity, significantly more than conventional full cells with a capacity of 79.2% remaining.

Anisotropic semi-aligned PAN@PVdF-HFP separator for Li-ion batteries

Compared with the common electrospun nanofibers, the alignment of the nanofibers exhibits interesting anisotropic mechanical properties and structural stability. In this paper, semi-aligned PAN@PVdF-HFP nanofiber separators were prepared by a modified electrospinning method. The composite separators exhibit anisotropic mechanical properties and enhanced electrochemical performance compared with electrospun PAN films. The PAN@PVdF-HFP nanofiber separator can deliver an ionic conductivity of 1.2 mSċcm^-1 with electrochemical stability up to 5.0 V. The LiFePO₄/Li cell with semi-aligned PAN@PVdF-HFP separator shows excellent cycling performance, good rate capability, as well as high discharge capacity.

A Fireproof, Lightweight, Polymer-Polymer Solid-State Electrolyte for Safe Lithium Batteries

Safety issues in lithium-ion batteries have raised serious concerns due to their ubiquitous utilization and close contact with the human body. Replacing flammable liquid electrolytes, solid-state electrolytes (SSEs) is thought to address this issue as well as provide unmatched energy densities in Li-based batteries. However, among the most intensively studied SSEs, polymeric solid electrolyte and polymer/ceramic composites are usually flammable, leaving the safety issue unattended. Here, we report the first design of a fireproof, ultralightweight polymer-polymer SSE. The SSE is composed of a porous mechanic enforcer (polyimide, PI), a fire-retardant additive (decabromodiphenyl ethane, DBDPE), and a ionic conductive polymer electrolyte (poly(ethylene oxide)/lithium bis(trifluoromethanesulfonyl)imide). The whole SSE is made from organic materials, with a thin, tunable thickness (10-25 μm), which endorse the energy density comparable to conventional separator/liquid electrolytes. The PI/DBDPE film is thermally stable, nonflammable, and mechanically strong, preventing Li-Li symmetrical cells from short-circuiting after more than 300 h of cycling. LiFePO₄/Li half cells with our SSE show a high rate performance (131 mAh g^-1 at 1 C) as well as cycling performance (300 cycles at C/2 rate) at 60 °C. Most intriguingly, pouch cells made with our polymer-polymer SSE still functioned well even under flame abuse tests.

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.

Preparation of Highly Porous PAN-LATP Membranes as Separators for Lithium Ion Batteries

Separators are a vital component to ensure the safety of lithium-ion batteries. However, the commercial separators employed in lithium ion batteries are inefficient due to their low porosity. In the present study, a simple electrospinning technique is adopted to prepare highly porous polyacrylonitrile (PAN)-based membranes with a higher concentration of lithium aluminum titanium phosphate (LATP) ceramic particles, as a viable alternative to the commercialized separators used in lithium ion batteries. The effect of the LATP particles on the morphology of the porous membranes is demonstrated through Field emission scattering electron microscopy. X-ray diffraction and Fourier transform infrared spectra studies suitably demonstrate the mixing of PAN and LATP particles in the polymer matrix. PAN with 30 wt% LATP (P-L30) exhibits an enhanced porosity of 90% and is more thermally stable, with the highest electrolyte uptake among all the prepared membranes. Due to better electrolyte uptake, the P-L30 membrane demonstrates an improved ionic conductivity of 1.7 mS/cm. A coin cell prepared with a P-L30 membrane and a LiFePO4 cathode demonstrates the highest discharge capacity of 158 mAh/g at 0.5 C-rate. The coin cell with the P-L30 membrane also displays good cycling stability by retaining 97.5% of the initial discharge capacity after 200 cycles of charging and discharging at a 1C rate.

Application of PVDF Organic Particles Coating on Polyethylene Separator for Lithium Ion Batteries

Surface coating modification on a polyethylene separator serves as a promising way to meet the high requirements of thermal dimensional stability and excellent electrolyte wettability for lithium ion batteries (LIBs). In this paper, we report a new type of surface modified separator by coating polyvinylidene fluoride (PVDF) organic particles on traditional microporous polyethylene (PE) separators. The PE separator coated by PVDF particles (PE-PVDF separator) has higher porosity (61.4%), better electrolyte wettability (the contact angle to water was 3.28° ± 0.21°) and superior ionic conductivity (1.53 mS/cm) compared with the bare PE separator (51.2%, 111.3° ± 0.12°, 0.55 mS/cm). On one hand, the PVDF organic polymer has excellent organic electrolyte compatibility. On the other hand, the PVDF particles contain sub-micro spheres, of which the separator can possess a large specific surface area to absorb additional electrolyte. As a result, LIBs assembled using the PE-PVDF separator showed better electrochemical performances. For example, the button cell using a PE-PVDF as the separator had a higher capacity retention rate (70.01% capacity retention after 200 cycles at 0.5 C) than the bare PE separator (62.5% capacity retention after 200 cycles at 0.5 C). Moreover, the rate capability of LIBs was greatly improved as well—especially at larger current densities such as 2 C and 5 C.

Recent Development in Separators for High-Temperature Lithium-Ion Batteries

Lithium-ion batteries (LIBs) are promising energy storage devices for integrating renewable resources and high power applications, owing to their high energy density, light weight, high flexibility, slow self-discharge rate, high rate charging capability, and long battery life. LIBs work efficiently at ambient temperatures, however, at high-temperatures, they cause serious issues due to the thermal fluctuation inside batteries during operation. The separator is a key component of batteries and is crucial for the sustainability of LIBs at high-temperatures. The high thermal stability with minimum thermal shrinkage and robust mechanical strength are the prime requirements along with high porosity, ionic conductivity, and electrolyte uptake for highly efficient high-temperature LIBs. This Review deals with the recent studies and developments in separator technologies for high-temperature LIBs with respect to their structural layered formation. The recent progress in monolayer and multilayer separators along with the developed preparation methodologies is discussed in detail. Future challenges and directions toward the advancement in separator technology are also discussed for achieving remarkable performance of separators in a high-temperature environment.

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.

Ion-Selective Polyamide Acid Nanofiber Separators for High-Rate and Stable Lithium-Sulfur Batteries

Lithium-sulfur (Li-S) batteries have attracted great attention because of their high energy density and high theoretical capacity. However, the "shuttle effect" caused by the dissolution of polysulfides in liquid electrolytes severely hinders their practical applications. Herein, we originally propose a carboxyl functional polyamide acid (PAA) nanofiber separator with dual functions for inhibiting polysulfide transfer and promoting Li⁺ migration via a one-step electrospinning synthesis method. Especially, the functional groups of -COOH in PAA separators provide an electronegative environment, which promotes the transport of Li⁺ but suppresses the migration of negative polysulfide anions. Therefore, the PAA nanofiber separator can act as an efficient electrostatic shield to restrict the polysulfide on the cathode side, while efficiently promoting Li⁺ transfer across the separator. As a result, an ultralow decay rate of only 0.12% per cycle is achieved for the PAA nanofiber separator after 200 cycles at 0.2 C, which is less than half that (0.26% per cycle) of the commercial Celgard separator.

Materials for lithium-ion battery safety

Lithium-ion batteries (LIBs) are considered to be one of the most important energy storage technologies. As the energy density of batteries increases, battery safety becomes even more critical if the energy is released unintentionally. Accidents related to fires and explosions of LIBs occur frequently worldwide. Some have caused serious threats to human life and health and have led to numerous product recalls by manufacturers. These incidents are reminders that safety is a prerequisite for batteries, and serious issues need to be resolved before the future application of high-energy battery systems. This Review aims to summarize the fundamentals of the origins of LIB safety issues and highlight recent key progress in materials design to improve LIB safety. We anticipate that this Review will inspire further improvement in battery safety, especially for emerging LIBs with high-energy density.

Nanofiller-incorporated porous polymer electrolyte for electrochemical energy storage devices

We report the poly(vinylidene fluoride-co-hexafluoropropylene) (PVdF-HFP)-based microporous polymer membranes, prepared by phase inversion technique, incorporated with different amounts of nanosized zirconium dioxide (ZrO2) filler. Scanning electron microscopy, X-ray diffraction, Fourier transform infrared spectroscopy and thermal studies confirm the role of ZrO2 nanofiller to modify the polymer structure, pore geometry and crystallinity. The nanofillers interact with the PVdF-HFP chains via surface groups and electrostatic interactions, and their incorporation led to an increase in crystalline content of the membrane and ionic conductivity (when activated with a liquid electrolyte (LE)). A possible mechanism for the increase in crystallinity in the polymer due to interaction with nanofiller particles has also been presented. The optimized membrane has been saturated with an LE sodium perchlorate-ethylene carbonate:propylene carbonate for use as a separator/electrolyte in electrical double-layer capacitor (EDLC). The cells fabricated with the nanofiller-incorporated membrane show better performance in terms of specific electrode capacitance, specific energy and specific power (approximately 76 F g−1, approximately 20.9 Wh kg−1 and 2.62 kW kg−1) than the cells using the membrane devoid of nanofillers (approximately 61 F g−1, approximately 17.3 Wh kg−1 and approximately 3.16 kW kg−1), respectively. The EDLC shows approximately 85% retention in specific capacitance for 10,000 charge–discharge cycles.

Superior Thermally Stable and Nonflammable Porous Polybenzimidazole Membrane with High Wettability for High-Power Lithium-Ion Batteries

Separators with high security, reliability, and rate capacity are in urgent need for the advancement of high power lithium ion batteries. The currently used porous polyolefin membranes are critically hindered by their low thermal stability and poor electrolyte wettability, which further lead to low rate capacity. Here we present a novel promising porous polybenzimidazole (PBI) membrane with super high thermal stability and electrolyte wettability. The rigid structure and functional groups in the PBI chain enable membranes to be stable at temperature as high as 400 °C, and the unique flame resistance of PBI could ensure the high security of a battery as well. In particular, the prepared membrane owns 328% electrolyte uptake, which is more than two times higher than commercial Celgard 2325 separator. The unique combination of high thermal stability, high flame resistance and super high electrolyte wettability enable the PBI porous membranes to be highly promising for high power lithium battery.