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

Manipulating the Nanophase Separation of a Polymer-Salt Microfluid Generates an Advanced In Situ Separator for Component-Integrated Energy Storage Devices

A polymer separator plays a pivotal role in battery safety, overall electrochemical performance, and cell assembly process. Traditional separators are separately produced from the electrodes and dominated by porous polyolefin thin films. In spite of their commercial success, today's separators are facing growing challenges with the increasing demand on the device safety and performance. As an attempt to address this urgent need, here, we propose a concept of in situ separator technology by manipulating the two-dimensional (2D) microfluid nanophase separation (2D-MFPS) of a poly(vinylidene difluoride)/lithium salt solution during drying. Particularly, nanophase separation is effectively regulated by low humidity, salt type, and compositions. For application studies, this 2D-MFPS is directly performed onto commercial electrodes under drying conditions with low humidity to fabricate a high-performance in situ separator with thickness and porous structures comparable to those of commercial Celgard separators. This in situ separator shows superior performance in high-temperature stability and wetting capability to a variety of liquid electrolytes. Finally, pouch cells with this in situ separator technology are successfully assembled with an extremely simplified separator-stacking-free process and demonstrate stable cycle performance due to the well-controlled porous structures and electrode-separator interface.

Spray fabrication of additive-free electrodes for advanced Lithium-Ion storage technologies

Polymer binders and carbon conductivity enhancers are inevitably required to make improvements in structural durability and electrochemical performance of lithium-ion battery (LIB) electrodes, although these additive constituents incur weight and volume penalties on the overall battery capacity. Here, additive-free electrode architectures were successfully fabricated over 20 × 20 cm2 electrode areas using a layer-by-layer spray coating approach, with the ultimate goal to boost gravimetric/volumetric electrode capacity and to reduce the total cost of LIB cells. Initially, the binder fraction of spray-coated Li4Ti5O12 (LTO) electrodes was reduced progressively, from 40 to 0 wt%. The electrochemical behavior of electrodes was then re-optimized as a proportion of conductivity enhancers within the binder-free electrode decreased to zero. Further, the otherwise identical spray coating process was applied to manufacture LiFePO4 (LFP) positive electrodes, leading to all-additive-free full-cell LIB configurations with attractive energy density of ∼310 Wh/kg and power performance of ∼1500 W/kg.