Zeolite membrane separators for fire-safe Li-ion batteries – Effects of crystal shape and membrane pore structure

The state-of-the-art lithium-ion batteries (LIB) use carbonate-based liquid electrolytes and polymeric separators which pose safety issues including fire-hazard. The use of fire-retarding salt-concentrated electrolytes can address the safety issues of LIBs, but these electrolytes have high viscosity and low wettability with polymeric separators making it difficult to fabricate high performance LIBs with the electrolytes. Here we report development of zeolite membrane separators with tailored pore structure and surface chemistry for preparation of fire-safe LIBs using salt-concentrated electrolytes. The zeolite membrane separators are made of zeolite particles with a specific zeolite structure, Si/Al ratio, and different particle shapes, coated on cathode by a scalable blade coating method. Intermediate pore, pure silica MFI-type zeolite (silicalite) was selected as the fire-proof material for membrane separators which also offer high wettability for the fire-retarding salt-concentrated electrolyte of lithium bis(fluorosulfonyl)imide (LiFSI) in tri-methyl phosphate solvent (TMP) solvent. Two silicalite membrane separators of similar pore size but different porosity and tortuosity were coated on cathode (LiNi_0.5Mn_0.3Co_0.2O₂ or NMC) using plate-shaped silicalite particles of low aspect ratio (LAR) and high aspect ratio (HAR). Both zeolite separators show significantly better wettability for the LiFSI/TMP electrolyte than the commercial polypropylene (PP) separator allowing fabrication of high-performance NMC/LiFSI-TMP/graphite cells with the non-combustible silicalite separator. The new fire-safe zeolite-membrane-based LIBs with the fire-retarding electrolyte exhibit excellent charge and discharge characteristics and cycle performance (similar to the state-of-the-art, but fire-unsafe LIBs with LiPF₆-carbonate electrolyte and polymer separator). The membrane separators made of HAR plate-shaped zeolite showing low interparticle porosity and high tortuosity perform better than the membrane made of LAR zeolite particles, due to a more uniform lithium-ion flux from both interparticle pores and intraparticle zeolitic pores at the separator/anode interface.