Polymer Binders: Characterization and Development toward Aqueous Electrode Fabrication for Sustainability

Multifunctional Cross-Linking Composite Binder Enables the Stable Performance of Si-Based Anodes for High-Energy-Density Lithium-Ion Batteries

The intrinsic volumetric stress during cycling is the main obstacle for developing Si-based materials as high-energy-density lithium-ion battery anodes. Elastic binders have been demonstrated as an efficient approach to alleviate the stress of Si. Herein, we design a tough 3D hard/soft polymeric network (LPTS) using lithiated poly(acrylic acid), silk sericin, and highly branched tannic acid. Covalent cross-linking provides a robust mechanical strength to endure the large stress. The formed multiple hydrogen bonds with bonding energies between 3.46 and 25 kcal mol-1 can effectively dissipate the stress through sequential hydrogen bond disassociation. The multifunctional LPTS binder maintains the integrity of the Si-based electrodes during repeated discharging/charging. Additionally, Li+ can be transferred via a Li-conducting group (-COOLi), thereby enhancing the ionic conductivity of electrodes. Consequently, the Si/LPTS electrode exhibits an improved initial Coulombic efficiency and excellent durability over 400 cycles. Meanwhile, this binder is also suitable for Si-C anodes, enabling stable cycling at a high areal capacity >3.6 mAh cm-2 and delivering 72.2% capacity retention for the LFP||Si-C/LPTS full cell after 200 cycles. This study provides insight into developing efficient Si-based binders that are facile and low-cost for next-generation high-energy-density systems.

Scalable slot-die coated flexible supercapacitors from upcycled PET face shields

Upcycling Covid19 plastic waste into valuable carbonaceous materials for energy storage applications is a sustainable and green approach to minimize the burden of waste plastic on the environment. Herein, we developed a facile single step activation technique for producing activated carbon consisting of spherical flower like carbon nanosheets and amorphous porous flakes from used PET [poly(ethylene terephthalate)] face shields for supercapacitor applications. The as-obtained activated carbon exhibited a high specific surface area of 1571 m2 g-1 and pore volume of 1.64 cm3 g-1. The specific capacitance of these carbon nanostructure-coated stainless steel electrodes reached 228.2 F g-1 at 1 A g-1 current density with excellent charge transport features and good rate capability in 1 M Na2SO4 aqueous electrolyte. We explored the slot-die coating technique for large-area coatings of flexible high-performance activated carbon electrodes with special emphasis on optimizing binder concentration. Significant improvement in electrochemical performance was achieved for the electrodes with 15 wt% Nafion concentration. The flexible supercapacitors fabricated using these electrodes showed high energy and power density of 21.8 W h kg-1 and 20 600 W kg-1 respectively, and retained 96.2% of the initial capacitance after 10 000 cycles at 2 A g-1 current density. The present study provides a promising sustainable approach for upcycling PET plastic waste for large area printable supercapacitors.

Polymeric Binder Design for Sustainable Lithium-Ion Battery Chemistry

The design of binders plays a pivotal role in achieving enduring high power in lithium-ion batteries (LIBs) and extending their overall lifespan. This review underscores the indispensable characteristics that a binder must possess when utilized in LIBs, considering factors such as electrochemical, thermal, and dispersion stability, compatibility with electrolytes, solubility in solvents, mechanical properties, and conductivity. In the case of anode materials, binders with robust mechanical properties and elasticity are imperative to uphold electrode integrity, particularly in materials subjected to substantial volume changes. For cathode materials, the selection of a binder hinges on the crystal structure of the cathode material. Other vital considerations in binder design encompass cost effectiveness, adhesion, processability, and environmental friendliness. Incorporating low-cost, eco-friendly, and biodegradable polymers can significantly contribute to sustainable battery development. This review serves as an invaluable resource for comprehending the prerequisites of binder design in high-performance LIBs and offers insights into binder selection for diverse electrode materials. The findings and principles articulated in this review can be extrapolated to other advanced battery systems, charting a course for developing next-generation batteries characterized by enhanced performance and sustainability.

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).

Bio-Based Binder Development for Lithium-Ion Batteries

The development of rechargeable lithium-ion battery (LIB) technology has facilitated the shift toward electric vehicles and grid storage solutions. This technology is currently undergoing significant development to meet industrial applications for portable electronics and provide our society with "greener" electricity. The large increase in LIB production following the growing demand from the automotive sector has led to the establishment of gigafactories worldwide, thus increasing the substantial consumption of fossil-based and non-sustainable materials, such as polyvinylidene fluoride and/or styrene-butadiene rubber as binders in cathode and anode formulations. Furthermore, the use of raw resources, such as Li, Ni, and Mn in cathode active materials and graphite and nanosilicon in anodes, necessitates further efforts to enhance battery efficiency. To foster a global sustainable transition in LIB manufacturing and reduce reliance on non-sustainable materials, the implementation of bio-based binder solutions for electrodes in LIBs is crucial. Bio-based binders such as cellulose, lignin, alginate, gums, starch, and others can address environmental concerns and can enhance LIBs' performance. This review aims to provide an overview of the current progress in the development and application of bio-based binders for LIB electrode manufacturing, highlighting their significance toward sustainable development.

In Situ Prepared Three-Dimensional Covalent and Hydrogen Bond Synergistic Binder to Boost the Performance of SiOx Anodes for Lithium-Ion Batteries

Polymer binders play an important role in enhancing the electrochemical performance of silicon-based anodes to alleviate the volume expansion for lithium-ion batteries. It is difficult for common one-dimensional (1D) linear binders to limit the volume expansion of a silicon-based electrode when combined with silicon-based particles with scant binding points. Therefore, it is necessary to design a three-dimensional (3D) network structure, which has multiple binding points with the silicon particles to dissipate the mechanical stress in the continuous charge and discharge circulation. Here, a covalent and hydrogen bond synergist 3D network green binder (poly(acrylic acid) (PAA)-dextrin 9 (Dex₉)) was prepared by the simple in situ thermal condensation of a one-dimensional liner binder PAA and Dex in the electrode fabrication process. The optimized SiO_x@PAA-Dex₉ electrode exhibits an initial Coulombic efficiency (ICE) of 82.4% at a current density of 0.2 A g^-1. At a high current density of 1 A g^-1, it retains a capacity of 607 mAh g^-1 after 300 cycles, which is approximately twice as high as that of the SiO_x@PAA electrode. Furthermore, the results of in situ electrochemical dilatometry (ECD) and characterization of electrode structures demonstrate that the PAA-Dex₉ binder can effectively buffer the huge volume change and maintain the integrity of the SiO_x electrodes. The research overcomes the low electrochemical stability difficulty of the 3D binder and sheds light on developing the simple fabrication procedure of an electrode.

Cathode-Electrolyte Interface Modification by Binder Engineering for High-Performance Aqueous Zinc-Ion Batteries

A stable cathode-electrolyte interface (CEI) is crucial for aqueous zinc-ion batteries (AZIBs), but it is less investigated. Commercial binder poly(vinylidene fluoride) (PVDF) is widely used without scrutinizing its suitability and cathode-electrolyte interface (CEI) in AZIBs. A water-soluble binder is developed that facilitated the in situ formation of a CEI protecting layer tuning the interfacial morphology. By combining a polysaccharide sodium alginate (SA) with a hydrophobic polytetrafluoroethylene (PTFE), the surface morphology, and charge storage kinetics can be confined from diffusion-dominated to capacitance-controlled processes. The underpinning mechanism investigates experimentally in both kinetic and thermodynamic perspectives demonstrate that the COO- from SA acts as an anionic polyelectrolyte facilitating the adsorption of Zn2+ ; meanwhile fluoride atoms on PTFE backbone provide hydrophobicity to break desolvation penalty. The hybrid binder is beneficial in providing a higher areal flux of Zn2+ at the CEI, where the Zn-Birnessite MnO2 battery with the hybrid binder exhibits an average specific capacity 45.6% higher than that with conventional PVDF binders; moreover, a reduced interface activation energy attained fosters a superior rate capability and a capacity retention of 99.1% in 1000 cycles. The hybrid binder also reduces the cost compared to the PVDF/NMP, which is a universal strategy to modify interface morphology.

The Influence of a Binder in a Composite Electrode: The Case Study of Vanadyl Phosphate in Aqueous Electrolyte

Layered VOPO₄·2H₂O is synthesized by the sonochemical method. An X-ray powder diffraction is used to examine the crystal structure, while scanning electron microscopy is used to reveal the morphology of the powder. The crystal structure refinement is performed in the P4/nmmZ space group. The electrochemical intercalation of several cations (Na⁺, Mg²⁺, Ca²⁺, and Al³⁺) in saturated nitrate aqueous solutions is investigated. The most notable reversible activity is found for the cycling in aluminium nitrate aqueous solution in the voltage range from -0.1 to 0.8 V vs. SCE. During the preparation of the electrode, it is observed that the structure is prone to changes that have not been recorded in the literature so far. Namely, the use of conventional binder PVDF in NMP solution deteriorates the structure and lowers the powder's crystallinity, while the use of Nafion solution causes the rearrangement of the atoms in a new crystal form that can be described in the monoclinic P2₁/c space group. Consequently, these structural changes affect electrochemical performances. The observed differences in electrochemical performances are a result of structural rearrangements.

Ion-Conducting Robust Cross-Linked Organic/Inorganic Polymer Composite as Effective Binder for Electrode of Electrochemical Capacitor

Poly(ionic liquid)s (PILs) are used in many electrochemical energy storage/conversion devices owing to their favorable physical properties. Therefore, PIL binders have been examined as polymeric binders for electrodes in energy storage systems (ESSs) and have shown superior performance. Several innovative technologies have been developed to improve the properties of polymers, with cross-linking being the most effective and easy strategy to achieve this. In this study, we designed a breakthrough complex cross-linking and composite technique that could successfully develop the physical properties of a polymer in a simple one-step process. Additionally, the technique could improve the thermal stability and mechanical properties of the polymer. The proposed polymeric binder showed better adhesion, higher capacitance, and good energy density with improved cyclic stability compared to that shown by conventional polyvinylidene fluoride (PVDF). This study revealed that cross-linked networks in polymeric binders are long-cycle-life features for electrochemical redox capacitors.

Solid Polymer Electrolytes for Lithium Batteries: A Tribute to Michel Armand

In a previous publication, a tribute to Michel Armand was provided, which highlighted his outstanding contribution to all aspects of research and development of lithium-metal and lithium-ion batteries. This area is in constant progress and rather than an overview of the work of Armand et al. since the seventies, we mainly restrict this review to his contribution to advances in solid polymer electrolytes (SPEs) and their performance in all-solid-state lithium-metal batteries in recent years.

Conductive Ink with Circular Life Cycle for Printed Electronics

Electronic waste carries energetic costs and an environmental burden rivaling that of plastic waste due to the rarity and toxicity of the heavy-metal components. Recyclable conductive composites are introduced for printed circuits formulated with polycaprolactone (PCL), conductive fillers, and enzyme/protectant nanoclusters. Circuits can be printed with flexibility (breaking strain ≈80%) and conductivity (≈2.1 × 10⁴ S m^-1 ). These composites are degraded at the end of life by immersion in warm water with programmable latency. Approximately 94% of the functional fillers can be recycled and reused with similar device performance. The printed circuits remain functional and degradable after shelf storage for at least 7 months at room temperature and one month of continuous operation under electrical voltage. The present studies provide composite design toward recyclable and easily disposable printed electronics for applications such as wearable electronics, biosensors, and soft robotics.

Single Lithium Ion Conducting "Binderlyte" for High-Performing Lithium Metal Batteries

Rechargeable lithium metal batteries (LMBs) are deemed as a viable solution to improve the power and/or energy density of the contemporary lithium-ion batteries (LIBs). However, poor Li-ion diffusivity within high-energy cathodes causes sluggish kinetics of the corresponding redox reactions particularly at high C-rates, thereby largely impeding the performance of rechargeable LMBs. In this work, a dual-functional single Li-ion conducting polysalt is proposed as both catholyte and binding agent (coined "Binderlyte") for rechargeable LMBs. The designed Binderlyte is thermally and electrochemically stable, allowing its use for high-energy cathodes like Li(Ni_1/3 Mn_1/3 Co_1/3 )O₂ (NMC111). The implementation of designer Binderlyte endows the Li° || NMC111 cell with superior cycling stability and capacity retention even at an extremely high C-rate of 10C. In particular, the soft and flexible nature of the Binderlyte allows the thick NMC cathode to operate at extremely low porosity (20 vol%) with almost no capacity decay. This work may provide a paradigm shift on the design of innovative polymeric materials, which are essential for developing high-performing rechargeable LMBs.

Thermal Stability and the Effect of Water on Hydrogen Fluoride Generation in Lithium-Ion Battery Electrolytes Containing LiPF6

Lithium-ion batteries (LIBs) have been used as electrochemical energy storage devices in various fields, ranging from mobile phones to electric vehicles. LIBs are composed of a positive electrode, a negative electrode, an electrolyte, and a binder. Among them, electrolytes consist of organic solvents and lithium ion conducting salts. The electrolytes used in LIBs are mostly linear and cyclic alkyl carbonates. These electrolytes are usually based on their combinations to allow the use of Li as the anodic active component, resulting in the high power and energy density of batteries. However, these organic electrolytes have high volatility and flammability that pose a serious safety issue when exposed to extreme conditions such as elevated temperatures. At that time, these electrolytes can react with active electrode materials and release a considerable amount of heat and gas. In this study, a simultaneous thermal analysis-mass spectrometry analysis was performed on six different organic solvents to examine the effect of water on hydrogen fluoride (HF) generation temperature in the electrolyte of a LIB. The electrolytes used in the experiment were anhydrous diethyl carbonate, 1,2-dimethoxyethane, ethylene carbonate, 1,3-dioxolane, tetrahydrofurfuryl alcohol, and 2-methyl-tetrahydrofuran, each containing LiPF6. The HF formation temperature was observed and compared with that when water entered the electrolyte exposed to high-temperature conditions such as fire.

Understanding the Solution Dynamics and Binding of a PVDF Binder with Silicon, Graphite, and NMC Materials and the Influence on Cycling Performance

The impact of the binding, solution structure, and solution dynamics of poly(vinylidene fluoride) (PVDF) with silicon on its performance as compared to traditional graphite and Li1.05Ni0.33Mn0.33Co0.33O2 (NMC) electrode materials was explored. Through refractive index (RI) measurements, the concentration of the binder adsorbed on the surface of electrode materials during electrode processing was determined to be less than half of the potentially available material resulting in excessive free binder in solution. Using ultrasmall-angle neutron scattering (USANS) and small-angle neutron scattering (SANS), it was found that PVDF forms a conformal coating over the entirety of the silicon particle. This is in direct contrast to graphite-PVDF and NMC-PVDF slurries, where PVDF only covers part of the graphite surface, and the PVDF chains make a network-like graphite-PVDF structure. Conversely, a thick layer of PVDF covers NMC particles, but the coating is porous, allowing for ion and electronic transport. The homogeneous coating of silicon breaks up percolation pathways, resulting in poor cycling performance of silicon materials as widely reported. These results indicate that the Si-PVDF interactions could be modified from a binder to a dispersant.

Frontiers and Structural Engineering for Building Flexible Zinc-Air Batteries

With the development of flexible devices, the demand for wearable power sources has increased and gradually become imperative. Zinc-air batteries (ZABs) have attracted lots of research interest due to their high theoretical energy density and excellent safety properties, which can meet the wearable energy supply requirements. Here, the flexibility of energy storage devices is discussed first, followed by the chemistries and development of flexible ZABs. The design of flexible electrodes, the properties of solid-state electrolytes (SSEs), and the construction of deformable structures are discussed in depth. The researchers working on flexible energy storage devices will benefit from the work.

A Comparative Evaluation of Sustainable Binders for Environmentally Friendly Carbon-Based Supercapacitors

Environmentally friendly energy storage devices have been fabricated by using functional materials obtained from completely renewable resources. Gelatin, chitosan, casein, guar gum and carboxymethyl cellulose have been investigated as sustainable and low-cost binders within the electrode active material of water-processable symmetric carbon-based supercapacitors. Such binders are selected from natural-derived materials and industrial by-products to obtain economic and environmental benefits. The electrochemical properties of the devices based on the different binders are compared by using cyclic voltammetry, galvanostatic charge/discharge curves and impedance spectroscopy. The fabricated supercapacitors exhibit series resistance lower than a few ohms and values of the specific capacitance ranged between 30 F/g and 80 F/g. The most performant device can deliver ca. 3.6 Wh/kg of energy at a high power density of 3925 W/kg. Gelatin, casein and carboxymethyl cellulose-based devices have shown device stability up to 1000 cycles. Detailed analysis on the charge storage mechanisms (e.g., involving faradaic and non-faradaic processes) at the electrode/electrolyte interface reveals a pseudocapacitance behavior within the supercapacitors. A clear correlation between the electrochemical performances (e.g., cycle stability, capacitance retention, series resistance value, coulombic efficiency) ageing phenomena and charge storage mechanisms within the porous carbon-based electrode have been discussed.