New flame-retardant composite separators based on metal hydroxides for lithium-ion batteries

Recent Progress of Advanced Functional Separators in Lithium Metal Batteries

As a representative in the post-lithium-ion batteries (LIBs) landscape, lithium metal batteries (LMBs) exhibit high-energy densities but suffer from low coulombic efficiencies and short cycling lifetimes due to dendrite formation and complex side reactions. Separator modification holds the most promise in overcoming these challenges because it utilizes the original elements of LMBs. In this review, separators designed to address critical issues in LMBs that are fatal to their destiny according to the target electrodes are focused on. On the lithium anode side, functional separators reduce dendrite propagation with a conductive lithiophilic layer and a uniform Li-ion channel or form a stable solid electrolyte interphase layer through the continuous release of active agents. The classification of functional separators solving the degradation stemming from the cathodes, which has often been overlooked, is summarized. Structural deterioration and the resulting leakage from cathode materials are suppressed by acidic impurity scavenging, transition metal ion capture, and polysulfide shuttle effect inhibition from functional separators. Furthermore, flame-retardant separators for preventing LMB safety issues and multifunctional separators are discussed. Further expansion of functional separators can be effectively utilized in other types of batteries, indicating that intensive and extensive research on functional separators is expected to continue in LIBs.

Functionalized γ-Boehmite Covalent Grafting Modified Polyethylene for Lithium-Ion Battery Separator

In the field of lithium-ion batteries, the challenges posed by the low melting point and inadequate wettability of conventional polyolefin separators have increased the focus on ceramic-coated separators. This study introduces a highly efficient and stable boehmite/polydopamine/polyethylene (AlOOH-PDA-PE) separator. It is crafted by covalently attaching functionalized nanosized boehmite (γ-AlOOH) whiskers onto polyethylene (PE) surfaces. The presence of a covalent bond increases the stability at the interface, while amino groups on the surface of the separator enhance the infiltration of the electrolyte and facilitate the diffusion of lithium ions. The PE-PDA-AlOOH separator, when used in lithium-ion batteries, achieves a discharge capacity of 126 mAh g-1 at 5 C and retains 97.1% capacity after 400 cycles, indicating superior cycling stability due to its covalently bonded ceramic surface. Thus, covalent interface modification is a promising strategy to prevent delamination of ceramic coatings in separators.

TiO2 Nanorod-Coated Polyethylene Separator with Well-Balanced Performance for Lithium-Ion Batteries

The thermal stability of the polyethylene (PE) separator is of utmost importance for the safety of lithium-ion batteries. Although the surface coating of PE separator with oxide nanoparticles can improve thermal stability, some serious problems still exist, such as micropore blockage, easy detaching, and introduction of excessive inert substances, which negatively affects the power density, energy density, and safety performance of the battery. In this paper, TiO₂ nanorods are used to modify the surface of the PE separator, and multiple analytical techniques (e.g., SEM, DSC, EIS, and LSV) are utilized to investigate the effect of coating amount on the physicochemical properties of the PE separator. The results show that the thermal stability, mechanical properties, and electrochemical properties of the PE separator can be effectively improved via surface coating with TiO₂ nanorods, but the degree of improvement is not directly proportional to the coating amount due to the fact that the forces inhibiting micropore deformation (mechanical stretching or thermal contraction) are derived from the interaction of TiO₂ nanorods directly "bridging" with the microporous skeleton rather than those indirectly "glued" with the microporous skeleton. Conversely, the introduction of excessive inert coating material could reduce the ionic conductivity, increase the interfacial impedance, and lower the energy density of the battery. The experimental results show that the ceramic separator with a coating amount of ~0.6 mg/cm² TiO₂ nanorods has well-balanced performances: its thermal shrinkage rate is 4.5%, the capacity retention assembled with this separator was 57.1% under 7 C/0.2 C and 82.6% after 100 cycles, respectively. This research may provide a novel approach to overcoming the common disadvantages of current surface-coated separators.

Challenges for Safe Electrolytes Applied in Lithium-Ion Cells-A Review

The aspect of safety in electronic devices has turned out to be a huge challenge for the world of science. Thus far, satisfactory power and energy densities, efficiency, and cell capacities have been achieved. Unfortunately, the explosiveness and thermal runaway of the cells prevents them from being used in demanding applications such as electric cars at higher temperatures. The main aim of this review is to highlight different electrolytes used in lithium-ion cells as well as the flammability aspect. In the paper, the authors present liquid inorganic electrolytes, composite polymer-ceramic electrolytes, ionic liquids (IL), polymeric ionic liquids, polymer electrolytes (solvent-free polymer electrolytes (SPEs), gel polymer electrolytes (GPEs), and composite polymer electrolytes (CPEs)), and different flame retardants used to prevent the thermal runaway and combustion of lithium-ion batteries (LIBs). Additionally, various flame tests used for electrolytes in LIBs have been adopted. Aside from a detailed description of the electrolytes consumed in LIBs. Last section in this work discusses hydrogen as a source of fuel cell operation and its practical application as a global trend that supports green chemistry.

Electrolyte-Resistant Dual Materials for the Synergistic Safety Enhancement of Lithium-Ion Batteries

Safety issues associated with lithium-ion batteries are of major concern, especially with the ever-growing demand for higher-energy-density storage devices. Although flame retardants (FRs) added to electrolytes can reduce fire hazards, large amounts of FRs are required and they severely deteriorate battery performance. Here, we report a feasible method to balance flame retardancy and electrochemical performance by coating an electrolyte-insoluble FR on commercial battery separators. By integrating dual materials via a two-pronged mechanism, the quantity of FR required could be limited to an ultrathin coating layer (4 μm) that rarely influences electrochemical performance. The developed composite separator has a four-times better flame retardancy than conventional polyolefin separators in full pouch cells. Additionally, this separator can be fabricated easily on a large scale for industrial applications. High-energy-density batteries (2 Ah) were assembled to demonstrate the scaling of the composite separator and to confirm its enhanced safety through nail penetration tests.

Fire-Safe Polymer Composites: Flame-Retardant Effect of Nanofillers

Currently, polymers are competing with metals and ceramics to realize various material characteristics, including mechanical and electrical properties. However, most polymers consist of organic matter, making them vulnerable to flames and high-temperature conditions. In addition, the combustion of polymers consisting of different types of organic matter results in various gaseous hazards. Therefore, to minimize the fire damage, there has been a significant demand for developing polymers that are fire resistant or flame retardant. From this viewpoint, it is crucial to design and synthesize thermally stable polymers that are less likely to decompose into combustible gaseous species under high-temperature conditions. Flame retardants can also be introduced to further reinforce the fire performance of polymers. In this review, the combustion process of organic matter, types of flame retardants, and common flammability testing methods are reviewed. Furthermore, the latest research trends in the use of versatile nanofillers to enhance the fire performance of polymeric materials are discussed with an emphasis on their underlying action, advantages, and disadvantages.

A Review of Experimental and Numerical Studies of Lithium Ion Battery Fires

Lithium-ion batteries (LIBs) are used extensively worldwide in a varied range of applications. However, LIBs present a considerable fire risk due to their flammable and frequently unstable components. This paper reviews experimental and numerical studies to understand parametric factors that have the greatest influence on the fire risks associated with LIBs. The LIB chemistry and the state of charge (SOC) are shown to have the greatest influence on the likelihood of a LIB transitioning into thermal runaway (TR) and releasing heats which can be cascaded to cause TR in adjacent cells. The magnitude of the heat release rate (HRR) is quantified to be used as a numerical model input parameter (source term). LIB chemistry, the SOC, and incident heat flux are proven to influence the magnitude of the HRR in all studies reviewed. Therefore, it may be conjectured that the most critical variables in addressing the overall fire safety and mitigating the probability of TR of LIBs are the chemistry and the SOC. The review of numerical modeling shows that it is quite challenging to reproduce experimental results with numerical simulations. Appropriate boundary conditions and fire properties as input parameters are required to model the onset of TR and heat transfer from thereon.

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.

A Review on the Thermal Hazards of the Lithium-Ion Battery and the Corresponding Countermeasures

As one of the most promising new energy sources, the lithium-ion battery (LIB) and its associated safety concerns have attracted great research interest. Herein, a comprehensive review on the thermal hazards of LIBs and the corresponding countermeasures is provided. In general, the thermal hazards of the LIB can be caused or aggravated by several factors including physical, electrical and thermal factors, manufacturing defect and even battery aging. Due to the activity and combustibility of traditional battery components, they usually possess a relatively high thermal hazard and a series of side reactions between electrodes and electrolytes may occur under abusive conditions, which would further lead to the thermal failure of LIBs. Besides, the thermal hazards generally manifest as the thermal runaway behaviors such as high-temperature, ejection, combustion, explosion and toxic gases for a single battery, and it can even evolve to thermal failure propagation within a battery pack. To decrease these hazards, some countermeasures are reviewed including the application of safety devices, fire-retardant additives, battery management systems, hazard warnings and firefighting should a hazard occur.

Effect of Varying the Ratio of Carbon Black to Vapor-Grown Carbon Fibers in the Separator on the Performance of Li⁻S Batteries

Lithium–sulfur (Li–S) batteries are expected to be very useful for next-generation transportation and grid storage because of their high energy density and low cost. However, their low active material utilization and poor cycle life limit their practical application. The use of a carbon-coated separator in these batteries serves to inhibit the migration of the lithium polysulfide intermediate and increases the recyclability. We report the extent to which the electrochemical performance of Li–S battery systems depends on the characteristics of the carbon coating of the separator. Carbon-coated separators containing different ratios of carbon black (Super-P) and vapor-grown carbon fibers (VGCFs) were prepared and evaluated in Li–S batteries. The results showed that larger amounts of Super-P on the carbon-coated separator enhanced the electrochemical performance of Li–S batteries; for instance, the pure Super-P coating exhibited the highest discharge capacity (602.1 mAh g⁻¹ at 150 cycles) with a Coulombic efficiency exceeding 95%. Furthermore, the separators with the pure Super-P coating had a smaller pore structure, and hence, limited polysulfide migration, compared to separators containing Super-P/VGCF mixtures. These results indicate that it is necessary to control the porosity of the porous membrane to control the movement of the lithium polysulfide.

Recent Advances in Poly(vinylidene fluoride) and Its Copolymers for Lithium-Ion Battery Separators

The separator membrane is an essential component of lithium-ion batteries, separating the anode and cathode, and controlling the number and mobility of the lithium ions. Among the polymer matrices most commonly investigated for battery separators are poly(vinylidene fluoride) (PVDF) and its copolymers poly(vinylidene fluoride-co-trifluoroethylene) (PVDF-TrFE), poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP), and poly(vinylidene fluoride-cochlorotrifluoroethylene) (PVDF-CTFE), due to their excellent properties such as high polarity and the possibility of controlling the porosity of the materials through binary and ternary polymer/solvent systems, among others. This review presents the recent advances on battery separators based on PVDF and its copolymers for lithium-ion batteries. It is divided into the following sections: single polymer and co-polymers, surface modification, composites, and polymer blends. Further, a critical comparison between those membranes and other separator membranes is presented, as well as the future trends on this area.

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).

Electrospun core-shell microfiber separator with thermal-triggered flame-retardant properties for lithium-ion batteries

Although the energy densities of batteries continue to increase, safety problems (for example, fires and explosions) associated with the use of highly flammable liquid organic electrolytes remain a big issue, significantly hindering further practical applications of the next generation of high-energy batteries. We have fabricated a novel "smart" nonwoven electrospun separator with thermal-triggered flame-retardant properties for lithium-ion batteries. The encapsulation of a flame retardant inside a protective polymer shell has prevented direct dissolution of the retardant agent into the electrolyte, which would otherwise have negative effects on battery performance. During thermal runaway of the lithium-ion battery, the protective polymer shell would melt, triggered by the increased temperature, and the flame retardant would be released, thus effectively suppressing the combustion of the highly flammable electrolytes.

Advanced Separators for Lithium-Ion and Lithium-Sulfur Batteries: A Review of Recent Progress

Li-ion and Li-S batteries find enormous applications in different fields, such as electric vehicles and portable electronics. A separator is an indispensable part of the battery design, which functions as a physical barrier for the electrode as well as an electrolyte reservoir for ionic transport. The properties of the separators directly influence the performance of the batteries. Traditional polyolefin separators showed low thermal stability, poor wettability toward the electrolyte, and inadequate barrier properties to polysulfides. To improve the performance and durability of Li-ion and Li-S batteries, development of advanced separators is required. In this review, we summarize recent progress on the fabrication and application of novel separators, including the functionalized polyolefin separator, polymeric separator, and ceramic separator, for Li-ion and Li-S batteries. The characteristics, advantages, and limitations of these separators are discussed. A brief outlook for the future directions of the research in the separators is also provided.

Preparation and evaluation of a separator with an asymmetric structure for lithium-ion batteries

Asymmetric separators with high porosity and thermal stability can provide different functionalities corresponding to the different interface properties at the cathode and anode surfaces.

Ceramic coated polypropylene separators for lithium-ion batteries with improved safety: effects of high melting point organic binder

A study on Al₂O₃/poly(vinyl alcohol) coated polypropylene separators is presented providing insights into designing high-performance LIB separators with improved safety.

Self-Extinguishing Lithium Ion Batteries Based on Internally Embedded Fire-Extinguishing Microcapsules with Temperature-Responsiveness

User safety is one of the most critical issues for the successful implementation of lithium ion batteries (LIBs) in electric vehicles and their further expansion in large-scale energy storage systems. Herein, we propose a novel approach to realize self-extinguishing capability of LIBs for effective safety improvement by integrating temperature-responsive microcapsules containing a fire-extinguishing agent. The microcapsules are designed to release an extinguisher agent upon increased internal temperature of an LIB, resulting in rapid heat absorption through an in situ endothermic reaction and suppression of further temperature rise and undesirable thermal runaway. In a standard nail penetration test, the temperature rise is reduced by 74% without compromising electrochemical performances. It is anticipated that on the strengths of excellent scalability, simplicity, and cost-effectiveness, this novel strategy can be extensively applied to various high energy-density devices to ensure human safety.