H₂O/HF Scavenging Mechanism in Cellulose-Based Separators for Lithium-Ion Batteries with Enhanced Cycle Life

Lithium-ion batteries (LIBs) are increasingly being integrated into the transportation industry due to their high energy density, durability, and low cost. With the growing demand for transportation and other emerging applications, there is a concurrent rise in concern over LIB material sourcing and recycling. This urges the development of LIBs with extended cycle lifespans. One mechanism of capacity fading in LIBs is the dissolution of transition metals into the electrolyte after the cathode is etched with hydrofluoric acid (HF). HF is readily generated by the hydrolysis of the LIB electrolyte salt, lithium hexafluorophosphate (LiPF₆), which makes minimizing moisture in the electrolyte a priority in manufacturing. In this study, a nonwoven, cellulose-based separator (CBS) is introduced as an alternative separator for battery technologies to scavenge residual water and HF from the electrolyte. The CBS is shown to be capable of scavenging varying amounts of water from the electrolyte based on different drying processes of the CBS, and a mechanism for this water scavenging is identified based on the materials present in the CBS. In addition, the chemical and electrochemical performance of the CBS in real battery conditions is investigated. Results suggest an effective H₂O/HF scavenging capability in the CBS that allows LIB coin cells to have over 17% higher capacity retention than those with conventional separators. Furthermore, studies of the industrially manufactured, commercially relevant cylindrical and pouch cells show remarkable 761 and 103% improvements in the 60% capacity lifetime, respectively. The environmental friendliness, low cost, and easy application empowered by the cycle life improvements shown in this work make this nonwoven CBS a promising candidate for improving industry-level LIB performance.