Zeolite Synthesis and Its Application as a Separator For Safe Li-ion and Li-metal Batteries

Lithium-ion and lithium-metal batteries represent a predominant energy storage solution with the potential to address the impending global energy crisis arising from limited non-renewable resources. However, these batteries face significant safety challenges that hinder their commercialization. The conventional polymeric separators and electrolytes have poor thermal stability and fireproof properties making them prone to thermal runaway that causes fire hazards and explosions when the battery is subjected to extreme operating conditions. To address this issue, various materials have been investigated for their use as separators. However, polymeric, and pure inorganic material-based separators have a trade-off between safety and electrochemical performance. This is where zeolites emerge as a promising solution, offering favorable thermal and electrochemical characteristics. The zeolites are coated onto the cathode as a separator using the scalable blade coating method. These separators are non-flammable with high thermal stability and electrolyte wettability. Furthermore, the presence of intracrystalline pores helps in homogenizing the Li-ion flux at anode resulting in improved electrochemical performance. This research delves into the preparation of zeolite separators using a commercial zeolite and lab-scale zeolite to study their safety and electrochemical performance in lithium-ion batteries. At low C-rates, both zeolites exhibited excellent capacity retention and capacity density displaying their potential to advance high-performance safe lithium-ion batteries. The commercial zeolite has demonstrated remarkable capacity retention and good performance in terms of charge and discharge cycles, as well as stability. This makes it a valuable resource for the scaling up of electrode-coated separator technology. Furthermore, the previous study demonstrated the superior electrochemical performance of plate silicalite separator (also a lab-made zeolite) with both lithium-ion and lithium-metal batteries. However, the process of scaling up and achieving precise control over plate silicalite particle size, and morphology using the existing synthesis procedure has proven challenging. Thus, the modification of process conditions is studied to enhance control over particle size, aspect ratio, and yield to facilitate a more efficient scaling-up process. Incorporation of stirring during the crystallization phase enhanced yield and uniformity of particle size. Also, the increase in temperature and time of crystallization enlarged the particles but did not show any significant improvement in the aspect ratio of the particles.