Nanoporous UHMWPE Membrane Separators for Safer and High-Power-Density Rechargeable Batteries

Battery safety has been of critical concerns and there are renewed interest in developing safer membranes for enhancing the inherent safety of lithium ion batteries. In this paper, the synthesis of a robust and safer self-reinforced composite ultrahigh molecular weight polyethylene (UHMWPE) membrane is described. The self-reinforced composite membrane consists of ≈200 nm nanopores homogeneously embedded inside interpenetrating nanofibrillar "shish kebab" networks. It performs thermal fuse function by selectively melting its kebab crystals while the elongated shish fibrillary backbones remain intact. Simulated thermal fuse function tests show that the newly prepared separator displays a 300% increase in tensile strength (550 MPa), 300% increase in puncture resistance (1.5 N μm^-1), as well as an 18 000 times increase in impedance when lateral dimensions are kept constant. Cells prepared using the UHMWPE separators also exhibit a 10% higher energy density and better cyclability than those using commercial separators. Hence, the newly prepared ultrathin and dimensionally stable membrane will enhance the safety protections for rechargeable batteries with low impedance for high energy and power density.