Low-Cost Mass Manufacturing Technique for the Shutdown-Functionalized Lithium-Ion Battery Separator Based on Al2O3 Coating Online Construction during the β-iPP Cavitation Process

Facile In Situ Building of Sulfonated SiO2 Coating on Porous Skeletons of Lithium-Ion Battery Separators

Polyolefin separators with worse porous structures and compatibilities mismatch the internal environment and deteriorate lithium-ion battery (LIB) combination properties. In this study, a sulfonated SiO2 (SSD) composited polypropylene separator (PP@SSD) is prepared to homogenize pore sizes and in situ-built SSD coatings on porous skeletons. Imported SSD uniformizes pore sizes owing to centralized interface distributions within casting films. Meanwhile, abundant cavitations enable the in situ SSD coating to facilely fix onto porous skeleton surfaces during separator fabrications, which feature simple techniques, low cost, environmental friendliness, and the capability for continuous fabrications. A sturdy SSD coating on the porous skeleton confines thermal shrinkages and offers a superior safety guarantee for LIBs. The abundant sulfonic acid groups of SSD endow PP@SSD with excellent electrolyte affinity, which lowers Li+ transfer barriers and optimizes interfacial compatibility. Therefore, assembled LIBs give the optimal C-rate capacity and cycling stability, holding a capacity retention of 82.7% after the 400th cycle at 0.5 C.

Yolk-Shell Structured ST@Al2 O3 Enables Functional PE Separator with Enhanced Lewis Acid Sites for High-Performance Lithium Metal Batteries

Commercial polymer separators usually have limited porosity, poor electrolyte wettability, and poor thermal and mechanical stability, which can deteriorate the performance of battery, especially at high current densities. In this work, a functional polyethylene (PE) separator is prepared by surface engineering a layer of Ti-doped SiO2 @Al2 O3 particles (denoted as ST@Al2 O3 -PE) with strong Lewis acid property and uniform porous structure on one side of the PE separator. On the other hand, ST@Al2 O3 particles with abundant pore structures and large cavities can store a large amount of electrolyte, providing a shortened pathway for lithium-ion transport, and the Lewis acid sites and porous structure of the ST@Al2 O3 can tune Li plating/stripping behavior and stabilize the lithium metal anode. The ST@Al2 O3 -PE separators exhibit better ionic conductivity (5.55 mS cm-1 ) and larger lithium-ion transference number (0.62). At a current density of 1 mA cm-2 , Li/Li symmetric cells with ST@Al2 O3 -PE separator can be stably cycled for more than 400 h, and both lithium iron phosphate /Li cells and lithium cobaltate/Li cells with ST@Al2 O3 -PE separator have good cycling and rate performance. This work provides a new strategy for developing functional separators and promoting the application of lithium metal batteries.

Grafting Polyethyleneimine-Poly(ethylene glycol) Gel onto a Heat-Resistant Polyimide Nanofiber Separator for Improving Lithium-Ion Transporting Ability in Lithium-Ion Batteries

To improve the lithium-ion transporting ability in lithium-ion batteries, a high-performance polyimide-based lithium-ion battery separator (PI-mod) was prepared by chemically grafting poly(ethylene glycol) (PEG) onto the surface of a heat-resistant polyimide nanofiber matrix with the assistance of amino-rich polyethyleneimine (PEI). The resulted PEI-PEG polymer coating exhibited unique gel-like properties with an electrolyte uptake rate of 168%, an area resistance as low as 2.60 Ω·cm², and an ionic conductivity up to 2.33 mS·cm^-1, which are 3.5, 0.10, and 12.3 times that of the commercial separator Celgard 2320, respectively. Meanwhile, the heat-resistant polyimide skeleton can effectively avoid thermal shrinkage of the modified separator even after 200 °C treatment for 0.5 h, which ensures the safety of the battery working under extreme conditions. The modified PI separator possessed a high electrochemical stability window of 4.5 V. Compared with the batteries from the commercial separator Celgard 2320 and the pure polyimide matrix, the assembled coin cell with the PI-mod separator showed much better rate capabilities and capacity retention due to the high electrolyte affinity of the PEI-PEG polymer coating. The developed strategy of using the electrolyte-swollen polymer to modify the thermal-resistant separator network provides an efficient way for establishing high-power lithium-ion batteries with good safety performance.

Class of Boehmite/Polyacrylonitrile Membranes with Different Thermal Shutdown Temperatures for High-Performance Lithium-Ion Batteries

Nowadays, lithium-ion batteries are required to have a higher energy density and safety because of their wide applications. Current commercial separators have poor wettability and thermal stability, which significantly impact the performance and safety of batteries. In this study, a class of boehmite particles with different grain sizes was synthesized by adjusting hydrothermal temperatures and used to fabricate boehmite/polyacrylonitrile (BM/PAN) membranes. All of these BM/PAN membranes can not only maintain excellent thermal dimensional stability above 200 °C but also have good electrolyte wettability and high porosity. More interestingly, the BM/PAN membranes' thermal shutdown temperature can be adjusted by changing the grain size of boehmite particles. The lithium-ion batteries assembled with BM/PAN separators exhibit different thermal stability phenomena at 150 °C and have excellent rate performance and cycle stability at room temperature. After 120 cycles at 1C, the LiFePO₄ half-cell assembled by the best BM/PAN separator has almost unchanged discharge capacity, whereas the capacity retention of Celgard 2325 is only about 85%. Meanwhile, the NCM523 half-cell assembled with the best BM/PAN separator shows superb cycle stability after 500 cycles at 8C, with a capacity retention of 79% compared with 56% for Celgard 2325.

Pilot Scale Hybrid Organic/Inorganic Coatings on a Polyolefin Separator to Enhance Dimensional Stability for Thermally Stable Long-Life Rechargeable Batteries

The electric vehicle and energy storage markets have grown rapidly in recent years. Thermal runaway caused by malfunctioning Li-ion batteries is an urgent issue with many causes (e.g., mechanical, electrical, and thermal abuse). The most common cause of thermal runaway is the formation of an internal short circuit because of damage to the separator. There has been significant effort to improve the design of separators, but to our knowledge, only inorganic nanoparticle coatings are used in commercial Li-ion batteries. Here, hybrid organic/inorganic coating layers are synthesized in a pilot-scale process that was developed from a crosslinkable polyamide-imide synthesis technique. The fabrication process is optimized to achieve reproducible hybrid organic/inorganic coating layers that are thin (≤4 μm), permeable (≤250 s/100 cc), and thermally stable beyond 150 °C. The hybrid coating layer is applied to mini-18650 Li-ion cells to show that the discharge capacity did not change at low discharge rates, and the retention capacity after 500 cycles was better than that of the reference cells used for comparison. This work demonstrates that a novel hybrid coating layer has the potential to improve the stability of commercial Li-ion batteries.

Toward Sustainable Solid Polymer Electrolytes for Lithium-Ion Batteries

Lithium-ion batteries (LIBs) are the most widely used energy storage system because of their high energy density and power, robustness, and reversibility, but they typically include an electrolyte solution composed of flammable organic solvents, leading to safety risks and reliability concerns for high-energy-density batteries. A step forward in Li-ion technology is the development of solid-state batteries suitable in terms of energy density and safety for the next generation of smart, safe, and high-performance batteries. Solid-state batteries can be developed on the basis of a solid polymer electrolyte (SPE) that may rely on natural polymers in order to replace synthetic ones, thereby taking into account environmental concerns. This work provides a perspective on current state-of-the-art sustainable SPEs for lithium-ion batteries. The recent developments are presented with a focus on natural polymers and their relevant properties in the context of battery applications. In addition, the ionic conductivity values and battery performance of natural polymer-based SPEs are reported, and it is shown that sustainable SPEs can become essential components of a next generation of high-performance solid-state batteries synergistically focused on performance, sustainability, and circular economy considerations.