Fabrication and Analysis of Near-Field Electrospun PVDF Fibers with Sol-Gel Coating for Lithium-Ion Battery Separator

Environmental and economic concerns are driving the demand for electric vehicles. However, their development for mass transportation hinges largely on improvements in the separators in lithium-ion batteries (LIBs), the preferred energy source. In this study, innovative separators for LIBs were fabricated by near-field electrospinning (NFES) and the sol-gel method. Using NFES, poly (vinylidene fluoride) (PVDF) fibers were fabricated. Then, PVDF membranes with pores of 220 nm and 450 nm were sandwiched between a monolayer and bilayer of the electrospun fibers. Nanoceramic material with organic resin, formed by the sol-gel method, was coated onto A4 paper, rice paper, nonwoven fabric, and carbon synthetic fabric. Properties of these separators were compared with those of a commercial polypropylene (PP) separator using a scanning electron microscope (SEM), microtensile testing, differential scanning calorimetry (DSC), ion-conductivity measurement, cyclic voltammetry (CV), and charge-discharge cycling. The results indicate that the 220 nm PVDF membrane sandwiched between a bilayer of electrospun fibers had excellent ionic conductivity (~0.57 mS/cm), a porosity of ~70%, an endothermic peak of ~175 °C, better specific capacitance (~356 mAh/g), a higher melting temperature (~160 °C), and a stable cycle performance. The sol-gel coated nonwoven fabric had ionic conductivity, porosity, and specific capacitance of ~0.96 mS/cm., ~64%, and ~220 mAh/g, respectively, and excellent thermal stability despite having a lower specific capacitance (65% of PP separator) and no peak below 270 °C. The present study provides a significant step toward the innovation of materials and processes for fabricating LIB separators.