Thermal, mechanical, and electrochemical stability enhancement of Al2O3 coated polypropylene/polyethylene/polypropylene separator via poly(vinylidene fluoride)-poly(ethoxylated pentaerythritol tetraacrylate) semi-interpenetrating network binder

Multiple uniform lithium-ion transport channels in Li6.4La3Zr1.4Ta0.6O12/Ce(OH)3 modified polypropylene composite separator for high-performance lithium metal batteries

Lithium (Li) metal anodes (LMAs) are regarded as leading technology for advanced-generation batteries due to their high theoretical capacity and favorable redox potential. However, the practical integration of LMAs into high-energy rechargeable batteries is hindered by the challenge of Li dendrite growth. In this work, nanoparticles of Li6.4La3Zr1.4Ta0.6O12 (LLZTO) loaded with Ce(OH)3 (LLZTCO) were designed and synthesized by a hydrothermal method. A functional composite separator was crafted by coating one side of a polypropylene (PP) separator with a composite electrolyte comprised of polyvinylidene fluoride (PVDF) and LLZTCO. The synergistic interactions between PVDF and LLZTCO provide numerous rapid lithium-ion (Li+) channels, facilitating the efficient redistribution of disparate Li+ flux originating from the insulated PP separator. The composite separator demonstrated an ionic conductivity (σ) of 3.68 × 10-3 S cm-1, substantial Li+ transference number (t+) of 0.73, and a high electrochemical window of 4.8 V at 25℃. Furthermore, the Li/LLZTCO@PP/Li symmetric cells demonstrated stable cycling for over 2000 h without significant dendrite formation. The Li/LiFePO4 (LFP) cells assembled with LLZTCO@PP separators exhibited a capacity retention of 91.6 % after 400 cycles at 1C. This study offers a practical approach to fabricating composite separators with enhanced safety and superior electrochemical performance.

Ultrathin, Mechanically Durable, and Scalable Polymer-in-Salt Solid Electrolyte for High-Rate Lithium Metal Batteries

Polymer-in-salt solid-state electrolytes (PIS SSEs) are emerging for high room-temperature ionic conductivity and facile handling, but suffer from poor mechanical durability and large thickness. Here, Al2O3-coated PE (PE/AO) separators are proposed as robust and large-scale substrates to trim the thickness of PIS SSEs without compromising mechanical durability. Various characterizations unravel that introducing Al2O3 coating on PE separators efficiently improves the wettability, thermal stability, and Li-dendrite resistance of PIS SSEs. The resulting PE/AO@PIS demonstrates ultra-small thickness (25 µm), exceptional mechanical durability (55.1 MPa), high decomposition temperature (330 °C), and favorable ionic conductivity (0.12 mS cm-1 at 25 °C). Consequently, the symmetrical Li cells remain stable at 0.1 mA cm-2 for 3000 h, without Li dendrite formation. Besides, the LiFePO4|Li full cells showcase excellent rate capability (131.0 mAh g-1 at 10C) and cyclability (93.6% capacity retention at 2C after 400 cycles), and high-mass-loading performance (7.5 mg cm-2). Moreover, the PE/AO@PIS can also pair with nickel-rich layered oxides (NCM811 and NCM9055), showing a remarkable specific capacity of 165.3 and 175.4 mAh g-1 at 0.2C after 100 cycles, respectively. This work presents an effective large-scale preparation approach for mechanically durable and ultrathin PIS SSEs, driving their practical applications for next-generation solid-state Li-metal batteries.

Advances in Polymer Binder Materials for Lithium-Ion Battery Electrodes and Separators

Lithium-ion batteries (LIBs) have become indispensable energy-storage devices for various applications, ranging from portable electronics to electric vehicles and renewable energy systems. The performance and reliability of LIBs depend on several key components, including the electrodes, separators, and electrolytes. Among these, the choice of binder materials for the electrodes plays a critical role in determining the overall performance and durability of LIBs. This review introduces polymer binders that have been traditionally used in the cathode, anode, and separator materials of LIBs. Furthermore, it explores the problems identified in traditional polymer binders and examines the research trends in next-generation polymer binder materials for lithium-ion batteries as alternatives. To date, the widespread use of N-methyl-2-pyrrolidone (NMP) as a solvent in lithium battery electrode production has been a standard practice. However, recent concerns regarding its high toxicity have prompted increased environmental scrutiny and the imposition of strict chemical regulations. As a result, there is a growing urgency to explore alternatives that are both environmentally benign and safer for use in battery manufacturing. This pressing need is further underscored by the rising demand for diverse binder research within the lithium battery industry. In light of the current emphasis on sustainability and environmental responsibility, it is imperative to investigate a range of binder options that can align with the evolving landscape of green and eco-conscious battery production. In this review paper, we introduce various binder options that can align with the evolving landscape of environmentally friendly and sustainable battery production, considering the current emphasis on battery performance enhancement and environmental responsibility.

Partially Neutralized Polyacrylic Acid as an Efficient Binder for Aqueous Ceramic-Coated Separators for Lithium-Ion Batteries

A partially neutralized polyacrylic acid (Pn-PAA) is used for coating sub-micron-sized α-alumina on a conventional microporous polyolefin separator, fabricating a ceramic-coated separator (CCS). Pn-PAA acts as a dispersant and binder by adsorbing itself on alpha(α)-alumina surfaces under acidic condition through the columbic interaction, providing a repulsive force to disperse fine alumina in aqueous suspension, and binds alumina strongly on plasma-treated separator through hydrogen bonding. This CCS shows favorable wettability in carbonate-based liquid electrolyte and ionic conduction due to the high hydrophilicity of Pn-PAA and alumina. With that, this study found that Pn-PAA-made-CCS yields a substantial adhesion strength of ~106 N/m with enhanced cycle stability, a specific capacity of 145.0 mAh/g after 200 cycles at 1 C at room temperature in half cells (LFP/Li metal).

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.

Dynamic Behavior of Thermally Affected Injection-Molded High-Density Polyethylene Parts Modified by Accelerated Electrons

Polyethylenes are the most widely used polymers and are gaining more and more interest due to their easy processability, relatively good mechanical properties and excellent chemical resistance. The disadvantage is their low temperature stability, which excludes particular high-density polyethylenes (HDPEs) for use in engineering applications where the temperature exceeds 100 °C for a long time. One of the possibilities of improving the temperature stability of HDPE is a modification by accelerated electrons when HDPE is cross-linked by this process and it is no longer possible to process it like a classic thermoplastic, e.g., by injection technology. The HDPE modified in this way was thermally stressed five times at temperatures of 110 and 160 °C, and then the dynamic tensile behavior was determined. The deformation and surface temperature of the specimens were recorded by a high-speed infrared camera. Furthermore, two thermal methods of specimen evaluation were used: differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The result of the measurement is that the modification of HDPE by accelerated electrons had a positive effect on the dynamic tensile behavior of these materials.

Quasi-Solid-State Polymer Electrolyte Based on Electrospun Polyacrylonitrile/Polysilsesquioxane Composite Nanofiber Membrane for High-Performance Lithium Batteries

Considering the safety problem that is caused by liquid electrolytes and Li dendrites for lithium batteries, a new quasi-solid-state polymer electrolyte technology is presented in this work. A layer of 1,4-phenylene bridged polysilsesquioxane (PSiO) is synthesized by a sol-gel way and coated on the electrospun polyacrylonitrile (PAN) nanofiber to prepare a PAN@PSiO nanofiber composite membrane, which is then used as a quasi-solid-state electrolyte scaffold as well as separator for lithium batteries (LBs). This composite membrane, consisting of the three-dimensional network architecture of the PAN nanofiber matrix and a mesoporous PSiO coating layer, exhibited a high electrolyte intake level (297 wt%) and excellent mechanical properties. The electrochemical analysis results indicate that the ionic conductivity of the PAN@PSiO-based quasi-solid-state electrolyte membrane is 1.58 × 10^-3 S cm^-1 at room temperature and the electrochemical stability window reaches 4.8 V. The optimization of the electrode and the composite membrane interface leads the LiFePO₄|PAN@PSiO|Li full cell to show superior cycling (capacity of 137.6 mAh g^-1 at 0.2 C after 160 cycles) and excellent rate performances.

Effect of Temperature Ageing on Injection Molded High-Density Polyethylene Parts Modified by Accelerated Electrons

The temperature ageing of high-density polyethylene (HDPE) modified by accelerated electrons was studied. Commodity plastic HDPE was used as a basic polymer material which was modified by radiation cross-linking. This polymer was used because of its excellent processability and chemical resistance. Plastic injection molding technology was used for the production of test specimens. These specimens were modified with the dose of radiation 33, 66, 99, 132, 165, and 198 kGy. The prepared specimens were tested to determine: gel content, degree of swelling, temperature stability, and changes in mechanical properties after temperature ageing. The results were determined by scanning electron microscopy (SEM) analysis on the fracture surfaces. The results of this study confirm that modification of HDPE by radiation cross-linking has a significant effect on increasing temperature stability. It has been shown that HDPE modified by radiation cross-linking can withstand temperatures exceeding the melting point of the original HDPE for a short-term.