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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 721 records · Page 40
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Prioritization of Early-Stage Research and Development of a Hydrogel-Encapsulated Anaerobic Technology for Distributed Treatment of High Strength Organic Wastewater

This study aims to support the prioritization of research and development (R&D) pathways of an anaerobic technology leveraging hydrogel-encapsulated biomass to treat high-strength organic industrial wastewaters, enabling decentralized energy recovery and treatment to reduce organic loading on centralized treatment facilities. To characterize the sustainability implications of early-stage design decisions and to delineate R&D targets, an encapsulated anaerobic process model was developed and coupled with design algorithms for integrated process simulation, techno-economic analysis, and life cycle assessment under uncertainty. Across the design space, a single-stage configuration with passive biogas collection was found to have the greatest potential for financial viability and the lowest life cycle carbon emission. Through robust uncertainty and sensitivity analyses, we found technology performance was driven by a handful of design and technological factors despite uncertainty surrounding many others. Hydraulic retention time and encapsulant volume were identified as the most impactful design decisions for the levelized cost and carbon intensity of chemical oxygen demand (COD) removal. Encapsulant longevity, a technological parameter, was the dominant driver of system sustainability and thus a clear R&D priority. Ultimately, we found encapsulated anaerobic systems with optimized fluidized bed design have significant potential to provide affordable, carbon-negative, and distributed COD removal from high strength organic wastewaters if encapsulant longevity can be maintained at 5 years or above.

Anaerobic Treatment↗
DOE OSTI2021

Comprehensive Insights into Nucleation, Autocatalytic Growth, and Stripping Efficiency for Lithium Plating in Full Cells

Synchrotron high-energy X-ray diffraction is used to enable nondestructive detection and quantification of heterogeneous lithium plating in working batteries. In this study a LiNi 0.5 Mn 0.3 Co 0.2 O 2 /graphite pouch cell was operated under 6C fast-charge rate for greater than 1200 cycles. The magnitude and spatial distribution of lithium plating, lithium stripping, and the effect of metallic lithium deposition on lithium intercalation into graphite were quantified. Fully intercalated graphite (LiC 6 ) was detected after discharge with a lateral distribution closely correlated with lithium plating, which can be used as a higher-sensitivity indicator for lithium plating. Over an extended cycle life, the overall metallic lithium concentration followed a sigmoidal curve indicating two-stage continuous nucleation and autocatalytic growth. The lithium stripping efficiency underwent an exponential decay as a function of cycle life as the buildup of metallic lithium hindered the efficient dissolution back into the electrolyte. The findings provide direct insights into the characteristics of lithium plating and stripping under realistic fast-charge conditions.

25 ENERGY STORAGE↗
DOE OSTI2025

A Combined Computational and Mathematical Analysis of Interconnect Fatigue Potential in Photovoltaic Modules

A finite element model of a 60-cell monocrystalline silicon glass-polymer photovoltaic module was simulated with ±1.0 kPa and ±2.4 kPa loads applied to the glass to calculate the deformation under load. Cell-to-cell displacements were used to approximate interconnect strain and stress. A mathematical fatigue cycle life relation was fitted to data for the interconnect material (copper), to generate a life prediction at each interconnect location based on the local stress means, reversal extents, and amplitudes. Interconnect stress was found to be significantly asymmetric about zero despite symmetric positive and negative module loads due to laminate thickness offsets about the neutral plane and the effects of module framing. Cycle life results indicated that interconnect fatigue failure was unlikely to occur over a 30-year lifetime of conservative wind and snow load cycles since the typical cell design feature of leaving some unconstrained length between the cell edge and first solder pad increases the effective gauge length and decreases the stress levels below the material endurance limit. Follow-up analyses found that 3.6 mm and 6.4 mm were the minimum unconstrained lengths required to survive the assumed lifetime of wind and snow cycles, respectively, confirming that typical industrial module constructions with 8–15 mm unconstrained lengths should survive conservatively. Notably, large magnitude, low-cycle snow loading was consistently the limiting factor requiring a longer unconstrained interconnect length. Finally, insights and workflows from this study inform module interconnection design limits for survival against mechanical fatigue in deployment environments.

14 SOLAR ENERGY↗
DOE OSTI2023

Racoons ( Procyon Lotor ) Show Higher Trypanosoma Cruzi Detection Rates than Virginia Opossums ( Didelphis Virginiana ) in South Carolina, USA

Chagas disease, a significant public health concern in the Americas, is caused by a protozoan parasite, Trypanosoma cruzi. The life cycle of T. cruzi involves kissing bugs (Triatoma spp.) functioning as vectors and mammalian species serving as hosts. Raccoons (Procyon lotor) and opossums (Didelphis virginiana) have been identified as important reservoir species in the life cycle of T. cruzi, but prevalence in both species in the southeastern US is currently understudied. We quantified T. cruzi prevalence in these two key reservoir species across our study area in South Carolina, US, and identified factors that may influence parasite detection. We collected whole blood from 183 raccoons and 126 opossums and used PCR to detect the presence of T. cruzi. We then used generalized linear models with parasite detection status as a binary response variable and predictor variables of land cover, distance to water, sex, season, and species. Our analysis indicated that raccoons experienced significantly higher parasite detection rates than Virginia opossums, with T. cruzi prevalence found to be 26.5% (95% confidence interval [CI], 20.0–33.8) in raccoons and 10.5% (95% CI, 5.51–17.5) in opossums. Altogether, our results concur with previous studies, in that T. cruzi is established in reservoir host populations in natural areas of the southeastern US.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Concurrently Approaching Volumetric and Specific Capacity Limits of Lithium Battery Cathodes via Conformal Pickering Emulsion Graphene Coatings

Abstract To achieve the high energy densities demanded by emerging technologies, lithium battery electrodes need to approach the volumetric and specific capacity limits of their electrochemically active constituents, which requires minimization of the inactive components of the electrode. However, a reduction in the percentage of inactive conductive additives limits charge transport within the battery electrode, which results in compromised electrochemical performance. Here, an electrode design that achieves efficient electron and lithium‐ion transport kinetics at exceptionally low conductive additive levels and industrially relevant active material areal loadings is introduced. Using a scalable Pickering emulsion approach, Ni‐rich LiNi 0.8 Co 0.15 Al 0.05 O 2 (NCA) cathode powders are conformally coated using only 0.5 wt% of solution‐processed graphene, resulting in an electrical conductivity that is comparable to 5 wt% carbon black. Moreover, the conformal graphene coating mitigates degradation at the cathode surface, thus providing improved electrochemical cycle life. The morphology of the electrodes also facilitates rapid lithium‐ion transport kinetics, which provides superlative rate capability. Overall, this electrode design concurrently approaches theoretical volumetric and specific capacity limits without tradeoffs in cycle life, rate capability, or active material areal loading.

Park, Kyu‐Young↗
DOE OSTI2026

TRIZ-Based Design Improvement for Facilitating Transmission Control Unit Remanufacturing

Design for Remanufacturing (DfRem) centers on enhancing product design and operations to facilitate remanufacturing while increasing both economic and environmental sustainability. DfRem requires a comprehensive understanding of product characteristics, production conditions, and operational constraints. Thus, DfRem requires a systematic methodology to identify and implement alternative designs. Among many critical steps in remanufacturing, disassembly is essential because it directly supports remanufacturing by separation of product components for cleaning, inspection, and other subsequent process steps. This study proposes a TRIZ-based framework to improve product design for disassembly in support of remanufacturing. The framework is applied to a transmission control unit (TCU) case study. The current TCU design prevents remanufacturing due to the sealant-based component joinery, which complicates disassembly and risks damaging the printed circuit board (PCB). After defining technical contradictions for the TCU product design and reviewing the suggested TRIZ principles to solve the conflicts, a cantilever snap-fit design alternative is developed. The economic feasibility of the snap-fit design is assessed by comparing the current and snap-fit design costs for three life cycles. The cost analysis demonstrates that the cost of the snap-fit design remains the same as the current design. Additionally, the snap-fit design offers substantial cost savings for three life cycles compared to the current design. We demonstrate how snap-fit design supports both environmental and economic sustainability.

42 ENGINEERING↗
DOE OSTI2024

Deconstructing the High Voltage Degradation Mechanisms in Na 2/3 Ni 1/3 Mn 2/3 O 2 with Single Crystals and Advanced Electrolyte

Abstract Sodium layered oxide cathodes can uniquely benefit from the existing lithium‐ion battery industry as sodium‐ion batteries gain traction as a potential low‐cost, drop‐in replacement. However, achieving relevant energy density with a suitable cycle life remains a challenge for sodium layered oxides. At high operating potentials, several competing degradation mechanisms prevent P2‐type Na 2/3 Ni 1/3 Mn 2/3 O 2 (≈550 Wh kg −1 ) from achieving meaningful cycle life—with bulk structural instability and surface reactivity being the primary retractors. Herein, the issue of particle cracking is addressed through detailed synthesis methods of “single‐crystal” materials. By comparison to a polycrystalline baseline, the single‐crystal materials quantify the capacity loss due to isolation of active material caused by intergranular particle cracking. The single crystal materials are then employed in cells with an advanced, “localized saturated electrolyte” (LSE) to demonstrate the magnitude of capacity loss due to electrolyte decomposition at the cathode surface. Mitigation of the surface reactivity through the LSE electrolyte effectively demonstrates the elevated importance of surface reactivity at high voltages despite the onset of egregious particle cracking. This work aims to guide future research into understanding molten‐salt assisted syntheses and advance the debate on surface versus bulk degradation.

Darga, Joe↗
DOE OSTI2024

Nutri‐cereal tissue‐specific transcriptome atlas during development: Functional integration of gene expression to identify mineral uptake pathways in little millet ( Panicum sumatrense )

SUMMARY Little millet (Panicum sumatrenseRoth ex Roem. & Schult.) is an essential minor millet of southeast Asia and Africa's temperate and subtropical regions. The plant is stress‐tolerant, has a short life cycle, and has a mineral‐rich nutritional profile associated with unique health benefits. We report the developmental gene expression atlas of little millet (genotype JK‐8) from ten tissues representing different stages of its life cycle, starting from seed germination and vegetative growth to panicle maturation. The developmental transcriptome atlas led to the identification of 342 827 transcripts. The BUSCO analysis and comparison with the transcriptomes of related species confirm that this study presents high‐quality, in‐depth coverage of the little millet transcriptome. In addition, the eFP browser generated here has a user‐friendly interface, allowing interactive visualizations of tissue‐specific gene expression. Using these data, we identified transcripts, the orthologs of which inArabidopsisand rice are involved in nutrient acquisition, transport, and response pathways. The comparative analysis of the expression levels of these transcripts holds great potential for enhancing the mineral content in crops, particularly zinc and iron, to address the issue of “hidden hunger” and to attain nutritional security, making it a valuable asset for translational research.

Plant Sciences↗
DOE OSTI2025

Mastering the Copolymerization Behavior of Ethyl Cyanoacrylate as Gel Polymer Electrolyte for Lithium‐metal Battery Application

Polymers with strong electron-withdrawing groups (e.g., cyano-containing polymers) are attractive for a wide range of applications due to their high dielectric constant and outstanding electrochemical stability. However, the polymerization of such monomers is difficult to control with trace of water affording instant reactions, and copolymerization with other monomers without using strong acid is even more challenging. The present study demonstrates a facile approach enabling efficient and controllable copolymerization of ethyl cyanoacrylate (ECA) without adding undesired additives, achieving mechanically robust and high ion-conduction gel polymer electrolyte (GPE) for safe and long cycle-life lithium-metal batteries (LMBs). The incorporated dual-lithium salts, i.e., lithium difluoro(oxalato)borate (LiDFOB) and lithium bis(trifluoromethanesulphonyl)imide (LiTFSI) not only facilitate radical polymerization of ECA monomers by suppressing their anionic polymerization, but also promote the formation of high-ionic conducting GPE. The incorporated methyl methacrylate (MMA) monomer accelerates the radical polymerization of ECA (confirmed by DFT calculations), achieving controlled copolymerization of ECA-based copolymers. Here, the mechanically robust polymer network made by the ECA copolymer enables LMBs with both LFP cathodes and high-voltage LCO cathodes (4.5 V) operatable at different temperatures with ultra-long cycle life at 1 C (capacity retention of 81.1 % and 83.8 %, respectively, over 1000 cycles).

Min, Weixing [Nankai University, Tianjin (China)]↗
DOE OSTI2022

Circular economy priorities for photovoltaics in the energy transition

Among the many ambitious decarbonization goals globally, the US intends grid decarbonization by 2035, requiring 1 TW of installed photovoltaics (PV), up from ~110 GW in 2021. This unprecedented global scale-up will stress existing PV supply chains with increased material and energy demands. By 2050, 1.75 TW of PV in the US cumulatively demands 97 million metric tonnes of virgin material and creates 8 million metric tonnes of life cycle waste. This analysis leverages the PV in Circular Economy tool (PV ICE) to evaluate two circular economy approaches, lifetime extension and closed-loop recycling, on their ability to reduce virgin material demands and life cycle wastes while meeting capacity goals. Modules with 50-year lifetimes can reduce virgin material demand by 3% through reduced deployment. Modules with 15-year lifetimes require an additional 1.2 TW of replacement modules to maintain capacity, increasing virgin material demand and waste unless >90% of module mass is closed-loop recycled. Currently, no PV technology is more than 90% closed-loop recycled. Glass, the majority of mass in all PV technologies and an energy intensive component with a problematic supply chain, should be targeted for a circular redesign. Our work contributes data-backed insights prioritizing circular PV strategies for a sustainable energy transition.

14 SOLAR ENERGY↗
DOE OSTI2023

CSAPR2 Optimized Convective Cell Tracking Data during TRACER

One of the challenges in analyzing convective cell properties is to observe the quick evolution of individual convective cells. While the operational radar data provide a volumetric data set to analyze radar observables of convective precipitation clouds, previous studies also suggested the quick evolution of cell life cycle that might not be captured by conventional radar volume scan strategies that take ~5-7 minutes. Aiming at enhancing our understanding of the links between convective cloud kinematic and microphysical processes as well as life cycles, the Tracking Aerosol Convection Interactions ExpeRiment (TRACER; Jensen et al. 2019) was conducted at Houston, Texas, in 2022. The TRACER campaign deployed the 2nd generation C-band Scanning ARM Precipitation Radar (CSAPR2), which performed frequent updates of range height indicator (RHI) and sector plan position indicator (PPI) scans to track individual convective cells every < 2 minutes, guided by a new cell tracking framework, Multisensor Agile Adaptive Sampling (MAAS; Kollias et al. 2020). This allows for capturing fast-evolving radar observables. We provide the processed CSAPR2 cell tracking data in CfRadial format collected during the TRACER field campaign from June to September 2022. The data files include processed radar variables: noise-masked reflectivity and differential reflectivity corrected for rain attenuation and systematic biases, noise-masked dealiased radial velocity, specific differential phase, locations of target cells (latitude, longitude, radar range), and radar-echo classification. Figure 1 provides an example of a 3D image of CSAPR2 reflectivity from the lowest PPI scan and an RHI scan after data processing.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Leveraging the bioeconomy for carbon drawdown

Stringent climate change mitigation scenarios rely on large-scale drawdown of carbon dioxide from the atmosphere. Amongst drawdown technologies, bioenergy with carbon capture and sequestration (BECCS) has received considerable attention in the climate mitigation literature. Recently, attention has shifted further from a relatively narrow focus on BECCS to a broader focus on Biomass Carbon Removal and Storage (BiCRS). The concept of BiCRS has the potential to enable a future where the climate mitigation value of biomass resources is more valuable than the energy value, due to the potential to remove and sequester large quantities atmospheric CO2. This article provides a qualitative overview of prominent BiCRS technologies from which a set of the most promising technologies are assessed quantitively through life cycle assessment. There are numerous opportunities to incorporate carbon removal and management within the bioeconomy, but the majority of immediate carbon removal potential exists in four bioproducts: bioenergy, bioplastics, biochar, and wood products. We analyze the life cycle greenhouse gas emissions and disposition of sequestered carbon over 10 000 years for four bioproducts representative of each broader category: an advanced BECCS pathway, biopolyethylene, oriented strand board, and biochar soil amendment. We find that the BECCS pathway has the greatest magnitude and durability of CO2 storage over all time horizons. However, non-BECCS pathways achieve 34–64% of the drawdown magnitude relative to BECCS and retain 55–67% of their initial drawdown over 100 years (central estimate). We identify three engineering strategies for enhancing carbon drawdown: reducing biomass supply chain emissions, maximizing carbon stored in long-lived products, and extending the term of carbon storage. Finally, we highlight the need to characterize both the magnitude and permanence of carbon drawdown as a means for policymakers and technology developers to deploy limited biomass resources to maximize mitigation benefits.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Leveraging the bioeconomy for carbon drawdown

Stringent climate change mitigation scenarios rely on large-scale drawdown of carbon dioxide from the atmosphere. Amongst drawdown technologies, bioenergy with carbon capture and sequestration (BECCS) has received considerable attention in the climate mitigation literature. Recently, attention has shifted further from a relatively narrow focus on BECCS to a broader focus on Biomass Carbon Removal and Storage (BiCRS). The concept of BiCRS has the potential to enable a future where the climate mitigation value of biomass resources is more valuable than the energy value, due to the potential to remove and sequester large quantities atmospheric CO 2 . This article provides a qualitative overview of prominent BiCRS technologies from which a set of the most promising technologies are assessed quantitively through life cycle assessment. There are numerous opportunities to incorporate carbon removal and management within the bioeconomy, but the majority of immediate carbon removal potential exists in four bioproducts: bioenergy, bioplastics, biochar, and wood products. We analyze the life cycle greenhouse gas emissions and disposition of sequestered carbon over 10,000 years for four bioproducts representative of each broader category: an advanced BECCS pathway, biopolyethylene, oriented strand board, and biochar soil amendment. We find that the BECCS pathway has the greatest magnitude and durability of CO 2 storage over all time horizons. However, non-BECCS pathways achieve 34–64% of the drawdown magnitude relative to BECCS and retain 55–67% of their initial drawdown over 100 years (central estimate). We identify three engineering strategies for enhancing carbon drawdown: reducing biomass supply chain emissions, maximizing carbon stored in long lived products, and extending the term of carbon storage. Finally, we highlight the need to characterize both the magnitude and permanence of carbon drawdown as a means for policymakers and technology develo pers to deploy limited biomass resources to maximize mitigation benefits.

09 BIOMASS FUELS↗
DOE OSTI2021

Efficient Lithium Metal Cycling over a Wide Range of Pressures from an Anion-Derived Solid-Electrolyte Interphase Framework

Advanced electrolytes were developed to improve the cyclability of lithium (Li) metal anodes, yet their working mechanisms remain unclear. Here, we study the Li cycling performance under different pressures in a 1 M Li bis(fluorosulfonyl)imide/fluorinated 1,4-dimethoxybutane electrolyte. A consistently long cycle life is achieved over a wide range of pressures (30–600 psi). We find that this is due to a completely different Li plating mode with more favorable deposition morphologies compared to that in a conventional carbonate electrolyte, which exhibits increasing cycle stability with increased pressure. We show that this is enabled by the properties of an anion-derived residual solid-electrolyte interphase (rSEI) framework on the electrode surface, an undercharacterized structure with profound implications for Li metal cycling. This anion-derived rSEI chemistry is likely the key to a prolonged cycle life of Li metal batteries and should be vigorously addressed in future electrolyte designs.

25 ENERGY STORAGE↗
DOE OSTI2024

Numerical coupling of aerosol emissions, dry removal, and turbulent mixing in the E3SM Atmosphere Model version 1 (EAMv1) – Part 2: A semi-discrete error analysis framework for assessing coupling schemes

Abstract. Part 1 (Wan et al., 2024) of this study discusses the motivation and empirical evaluation of a revision to the aerosol-related numerical process coupling in the atmosphere component of the Energy Exascale Earth System Model version 1 (EAMv1) to address the previously reported issue of strong sensitivity of the simulated dust aerosol lifetime and dry removal rate to the model's vertical resolution. This paper complements that empirical justification of the revised scheme with a mathematical justification leveraging a semi-discrete analysis framework for assessing the splitting error of process coupling methods. The framework distinguishes the error due to numerical splitting from the error due to the time integration method(s) used for each individual process. Such a distinction results in a framework that provides an intuitive understanding of the causes of the splitting error. The application of this framework to the dust life cycle in EAMv1 confirms (i) that the original EAMv1 scheme artificially strengthens the effect of dry removal processes and (ii) that the revised splitting reduces that artificial strengthening. While the error analysis framework is presented in the context of the dust life cycle in EAMv1, the framework can be broadly leveraged to evaluate process coupling schemes, both in other physical problems and for any number of processes. This framework will be particularly powerful when the various process implementations support a variety of time integration approaches. Whereas traditional local truncation error approaches require separate consideration of each combination of time integration methods, this framework enables evaluation of coupling schemes independent of particular time integration approaches for each process while still allowing for the incorporation of these specific time integration errors if so desired. The framework also explains how the splitting error terms result from (i) the integration of individual processes in isolation from other processes and (ii) the choices of input state and time step size for the isolated integration of processes. Such a perspective has the potential for the rapid development of alternative coupling approaches that utilize knowledge both about the desired accuracy and about the computational costs of individual processes.

58 GEOSCIENCES↗
DOE OSTI2021

High Depth‐of‐Discharge Zinc Rechargeability Enabled by a Self‐Assembled Polymeric Coating

Abstract Zinc has the potential for widespread use as an environmentally friendly and cost‐effective anode material pending the resolution of rechargeability issues caused by active material loss and shape change. Here, a self‐assembled Nafion‐coated Celgard 3501 (NC‐Celgard) separator is shown to enable unprecedented cycle life of a Zn anode in alkaline electrolyte at high depth‐of‐discharge (DOD Zn ). Using commercially relevant energy‐dense electrodes with high areal capacities of 60 mAh cm –2 , Zn–Ni cells tested at 20% DOD Zn cells achieve over 200 cycles while 50% DOD Zn cells achieve over 100 cycles before failure. The 20% and 50% DOD cells deliver an average of 132 and 180 Wh L –1 per cycle over their lifetime respectively. Rechargeability is attributed to the highly selective diffusion properties of the 300 nm thick negatively charged Nafion coating on the separator which prevents shorting by dendrites and inhibits redistribution of the active material. Crossover experiments show that the NC‐Celgard separator is practically impermeable to zincate ([Zn(OH) 4 ] 2– ), outperforming commercial Celgard, cellophane, Nafion 211 and 212 separators while still allowing hydroxide transport. This work demonstrates the efficacy of selective separators for increasing the cycle life of energy‐dense Zn electrodes without adding significant volume or complexity to the system.

Arnot, David J.↗
DOE OSTI2021

Fluorination-Enhanced Surface Stability of Cation-Disordered Rocksalt Cathodes for Li-Ion Batteries

Cation-disordered rocksalt (DRX) materials have emerged as a class of novel high-capacity cathodes for Li-ion batteries. However, commercialization of DRX cathodes will require reducing their capacity decay, which has been associated with oxygen loss during cycling. Recent studies have shown that fluorination of DRX cathodes can effectively reduce the oxygen loss and improve the cycling stability; however, the underlying atomic-scale mechanisms remain elusive. Herein, using a combination of electrochemical measurements, scanning transmission electron microscopy, and electron energy loss spectroscopy, we examine the correlation between the electrochemical properties and structural evolution in Mn-redox-based DRX cathodes, Li1.2Ti0.4-xMn0.4+xO2.0-xFx (x = 0 and 0.2). We find that fluorination strongly suppresses structural amorphization and void formation initiated from the particle surface, therefore greatly enhancing the cyclability of the cathode. We further reveal a novel rocksalt-to-spinel-like structural transformation in the DRX bulk, which surprisingly contributes to a gradual capacity increase during cycling. Our results provide important insight for the design of novel DRX cathodes with high capacity and long cycle life.

Li, Linze↗
DOE OSTI2024

3D Printed Nanoporous Separators Based on Polymerization-Induced Phase Separation for Fast-Charging, High Cycling Stability Li-Ion Batteries

Fast charging and stable lithium-ion batteries (LIBs) require prompt Li ion transport between electrodes. 3D porous separators can potentially improve ion transport at both the microscale and macroscale levels. Additive manufacturing (AM) is an ideal tool to produce and study 3D porous separators of LIBs, although little work has been reported in this area. Here, we demonstrate porous structural control in layer-by-layer printed hexanediol diacrylate (HDDA) separators using a projection micro stereolithography (PμSL) AM technology and present their corresponding battery performance in lithium nickel manganese cobalt oxide (NMC)/graphite full cells. The composition of photocurable resin determines the porous morphology (e.g., bicontinuous and droplet-like), while the settings of printing layer thickness and number of exposures can be used to adjust the porosity (e.g., from 27% to 63%). Optimal resin and print conditions are determined, and the resulting separator exhibits superior Li ion conductivity and therefore higher rate performance and longer cycling life. Compared with a Celgard 2325 separator, the optimized porous HDDA separator increases the 10C-rate capacity by 34% and decreases the capacity degradation rate at the 1C-rate by 4.9%. In conclusion, this work paves the way for future AM of 3D separators for high-energy, high-power, and long-cycling-life LIBs.

25 ENERGY STORAGE↗