Stretchable Lithium‐Ion Batteries Enabled by Device‐Scaled Wavy Structure and Elastic‐Sticky Separator

Fast developments and substantial achievements have been shaping the field of wearable electronic devices, resulting in the persistent requirement for stretchable lithium‐ion batteries (LIBs). Despite recent progress in stretchable electrodes, stretching full batteries, including electrodes, separator, and sealing material, remains a great challenge. Here, a simple design concept for stretchable LIBs via a wavy structure at the full battery device scale is reported. All components including the package are capable of being reversibly stretched by folding the entire pouch cell into a wavy shape with polydimethylsiloxane filled in each valley region. In addition, the stretchable, sticky, and porous polyurethane/poly(vinylidene fluoride) membrane is adopted as a separator for the first time, which can maintain intimate contact between electrodes and separator to continuously secure ion pathway under dynamic state. Commercial cathode, anode, and package can be utilized in this rationally designed wavy battery to enable stretchability. The results indicate good electrochemical performances and long‐term stability at repeatable release–stretch cycles. A high areal capacity of 3.6 mA h cm^?2 and energy density of up to 172 W h L^?1 can be achieved for the wavy battery. The promising results of the cost‐effective wavy battery with high stretchability shed light on the development of stretchable energy storages.     

Super‐Stretchable Zinc–Air Batteries Based on an Alkaline‐Tolerant Dual‐Network Hydrogel Electrolyte

Stretchable devices need elastic hydrogel electrolyte as an essential component, while most hydrogels will lose their stretchability after being incorporated with strong alkaline solution. This is why highly stretchable zinc–air batteries have never been reported so far. Herein, super‐stretchable, flat‐ (800% stretchable) and fiber‐shaped (500% stretchable) zinc–air batteries are first developed by designing an alkaline‐tolerant dual‐network hydrogel electrolyte. In the dual‐network hydrogel electrolyte, sodium polyacrylate (PANa) chains contribute to the formation of soft domains and the carboxyl groups neutralized by hydroxyls as well as cellulose as potassium hydroxide stabilizer are responsible for vastly enhanced alkaline tolerance. The obtained super‐stretchable, flat zinc–air battery exhibits a high power density of 108.6 mW?cm^?2, increasing to 210.5 mW?cm^?2 upon being 800% stretched. Similar phenomena are observed for the 500% stretchable fiber‐shaped batteries. The devices can maintain stable power output even after being heavily deformed benefiting from the highly soft, alkaline‐tolerant hydrogel electrolyte developed. A bendable battery‐display system and water proof weavable fiber zinc–air battery are also demonstrated. This work will facilitate the progress of using zinc–air battery powering flexible electronics and smart clothes. Moreover, the developed alkaline‐tolerant super‐stretchable electrolyte can also be applied for many other alkaline electrolyte‐based energy storage/conversion devices.     

Highly Stretchable Separator Membrane for Deformable Energy‐Storage Devices

With the emergence of stretchable electronic devices, there is growing interest in the development of deformable power accessories that can power them. To date, various approaches have been reported for replacing rigid components of typical batteries with elastic materials. Little attention, however, has been paid to stretchable separator membranes that can not only prevent internal short circuit but also provide an ionic conducting pathway between electrodes under extreme physical deformation. Herein, a poly(styrene‐b‐butadiene‐b‐styrene) (SBS) block copolymer–based stretchable separator membrane is fabricated by the nonsolvent‐induced phase separation (NIPS). The diversity of mechanical properties and porous structures can be obtained by using different polymer concentrations and tuning the affinity among major components of NIPS. The stretchable separator membrane exhibits a high stretchability of around 270% strain and porous structure having porosity of 61%. Thus, its potential application as a stretchable separator membrane for deformable energy devices is demonstrated by applying to organic/aqueous electrolyte–based rechargeable lithium‐ion batteries. As a result, these batteries manifest good cycle life and stable capacity retention even under a stretching condition of 100%, without compromising the battery's performance.     

All‐Manganese‐Based Binder‐Free Stretchable Lithium‐Ion Batteries

Advanced electrode materials with bendability and stretchability are critical for the rapid development of fully flexible/stretchable lithium‐ion batteries. However, the sufficiently stretchable lithium‐ion battery is still underdeveloped that is one of the biggest challenges preventing from realizing fully deformable power sources. Here, a low‐temperature hydrothermal synthesis of a cathode material for stretchable lithium‐ion battery is reported by the in situ growth of LiMn₂O₄ (LMO) nanocrystals inside 3D carbon nanotube (CNT) film networks. The LMO/CNT film composite has demonstrated the chemical bonding between the LMO active materials and CNT scaffolds, which is the most important characteristic of the stretchable electrodes. When coupled with a wrinkled MnO_x /CNT film anode, a binder‐free, all‐manganese‐based stretchable full battery cell is assembled which delivers a high average specific capacity of ≈97 mA h g^?1 and stabilizes after over 300 cycles with an enormous strain of 100%. Furthermore, combining with other merits such as low cost, natural abundance, and environmentally friendly, the all‐manganese design is expected to accelerate the practical applications of stretchable lithium‐ion batteries for fully flexible and biomedical electronics.     

All‐Printed,Stretchable Zn‐Ag2O Rechargeable Battery via Hyperelastic Binder for Self‐Powering Wearable Electronics

While several stretchable batteries utilizing either deterministic or random composite architectures have been described, none have been fabricated using inexpensive printing technologies. In this study, the authors printed a highly stretchable, zinc‐silver oxide (Zn‐Ag₂O) battery by incorporating polystyrene‐block ‐polyisoprene‐block ‐polystyrene (SIS) as a hyperelastic binder for custom‐made printable inks. The remarkable mechanical properties of the SIS binder lead to an all‐printed, stretchable Zn‐Ag₂O rechargeable battery with a ≈2.5 mA h cm^?2 reversible capacity density even after multiple iterations of 100% stretching. This battery offers the highest reversible capacity and discharge current density for intrinsically stretchable batteries reported to date. The electrochemical and mechanical properties are characterized under different strain conditions. The new stress‐enduring printable inks pave ways for further developing stretchable electronics for the wide range of wearable applications.     

Autonomic Shutdown of Lithium‐Ion Batteries Using Thermoresponsive Microspheres

Autonomic, thermally‐induced shutdown of Lithium‐ion (Li‐ion) batteries is demonstrated by incorporating thermoresponsive polymer microspheres (ca. 4 μm) onto battery anodes or separators. When the internal battery environment reaches a critical temperature, the microspheres melt and coat the anode/separator with a nonconductive barrier, halting Li‐ion transport and shutting down the cell permanently. Three functionalization schemes are shown to perform cell shutdown: 1) poly(ethylene) (PE) microspheres coated on the anode, 2) paraffin wax microspheres coated on the anode, and 3) PE microspheres coated on the separator. Charge and discharge capacity is measured for Li‐ion coin cells containing microsphere‐coated anodes or separators as a function of capsule coverage. For PE coated on the anode, the initial capacity of the battery is unaffected by the presence of the PE microspheres up to a coverage of 12 mg cm^?2 (when cycled at 1C), and full shutdown (>98% loss of initial capacity) is achieved in cells containing greater than 3.5 mg cm^?2. For paraffin microspheres coated on the anode and PE microspheres coated on the separator, shutdown is achieved in cells containing coverages greater than 2.9 and 13.7 mg cm^?2, respectively. Scanning electron microscopy images of electrode surfaces from cells that have undergone autonomic shutdown provides evidence of melting, wetting, and resolidification of PE into the anode and polymer film formation at the anode/separator interface.     

Highly Stable Lithium–Sulfur Batteries Based on Laponite Nanosheet‐Coated Celgard Separators

Lithium–sulfur (Li–S) batteries are of great interest due to their high theoretical energy density. However, one of the key issues hindering their real world applications is polysulfide shuttle, which results in severe capacity decay and self‐discharge. Here, a laponite nanosheets/carbon black coated Celgard (LNS/CB‐Celgard) separator to inhibit polysulfide shuttle and to enhance the Li⁺ conductivity simultaneously is reported. The polysulfide shuttle is efficiently inhibited through strong interactions between the O active sites of the LNS and polysulfides by forming the Li···O and O? S bonds. Moreover, the separator features high Li⁺ conductivity, fast Li⁺ diffusion, excellent electrolyte wettability, and high thermal stability. Consequently, the Li–S batteries with the LNS/CB‐Celgard separator and the pure S cathode show a high initial reversible capacity of 1387 mA h g^?1 at 0.1 C, high rate performance, superior cycling stability (with a capacity decay rate of 0.06% cycle^?1 at 0.2 C and 0.028% cycle^?1 at 1.0 C over 500 cycles), and ultralow self‐discharge. The separator could also enhance the performance of other batteries such as the LiFePO₄/separator/Li battery. This work sheds a new light on the design and preparation of novel separators for highly stable Li–S batteries via a “green” and cost‐effective approach.     

Interface Engineering of MXene Composite Separator for High‐Performance Li–Se and Na–Se Batteries

Selenium (Se), due to its high electronic conductivity and high energy density, has recently attracted considerable interest as a cathode material for rechargeable Li/Na batteries. However, the poor cycling stability originating from the severe shuttle effect of polyselenides hinders their practical applications. Herein, highly stable Li/Na–Se batteries are developed using ultrathin (≈270 nm, loading of 0.09 mg cm^?2) cetrimonium bromide (CTAB)/carbon nanotube (CNT)/Ti₃C₂T_x MXene hybrid modified polypropylene (PP) (CCNT/MXene/PP) separators. The hybrid separator can immobilize the polyselenides via enhanced Lewis acid–base interactions between CTAB/MXene and polyselenides, which is demonstrated by theoretical calculations and X‐ray photoelectron spectroscopy. The incorporation of CNT helps to improve the electrolyte infiltration and facilitate the ionic transport. In situ permeation experiments are conducted for the first time to visually study the behavior of polyselenides, revealing the prohibited shuttle effect and protected Li anode from corrosion with CCNT/MXene/PP separators. As a result, the Li–Se batteries with CCNT/MXene/PP separators deliver an outstanding cycling performance over 500 cycles at 1C with an extremely low capacity decay of 0.05% per cycle. Moreover, the hybrid separators also perform well in Na–Se batteries. This study develops a preferable separator–electrolyte interface and the concept can be applied in other conversion‐type battery systems.     

Hexagonal Boron Nitride‐Based Electrolyte Composite for Li‐Ion Battery Operation from Room Temperature to 150 °C

Batteries for high temperature applications capable of withstanding over 60 °C are still dominated by primary cells. Conventional rechargeable energy storage technologies which have exceptional performance at ambient temperatures employ volatile electrolytes and soft separators, resulting in catastrophic failure under heat. A composite electrolyte/separator is reported that holds the key to extend the capability of Li‐ion batteries to high temperatures. A stoichiometric mixture of hexagonal boron nitride, piperidinium‐based ionic liquid, and a lithium salt is formulated, with ionic conductivity reaching 3 mS cm^?1, electrochemical stability up to 5 V and extended thermal stability. The composite is used in combination with conventional electrodes and demonstrates to be stable for over 600 cycles at 120 °C, with a total capacity fade of less than 3%. The ease of formulation along with superior thermal and electrochemical stability of this system extends the use of Li‐ion chemistries to applications beyond consumer electronics and electric vehicles.     

Rechargeable Soft‐Matter EGaIn‐MnO2 Battery for Stretchable Electronics

A rechargeable, stretchable battery composed of a liquid metal alloy (eutectic gallium‐indium; EGaIn) anode, a carbon paste, and MnO₂ slurry cathode, an alkaline electrolytic hydrogel, and a soft elastomeric package is presented. The battery can stably cycle within a voltage range of 1.40–1.86 V at 1 mA cm^?2 while being subject to 100% tensile strain. This is accomplished through a mechanism that involves reversible stripping and plating of gallium along with MnO₂ chemical conversion. Moreover, a technique to increase the contact area between the EGaIn anode and hydrogel interface using CaCl₂ additives, which reduces polarization and therefore reduces the effective current density, leading to higher discharge plateaus and lower charge plateaus. Relative to previous attempts at energy storage with liquid metal, the EGaIn‐MnO₂ battery presented here shows an exceptional areal specific capacity (≈3.8 mAh cm^?2) and robust, stable rechargeability over >100 charging cycles. The battery is also stable under bending, with negligible change in electrochemical properties when bent to a 2 mm radius of curvature. Batteries embedded within a wearable elastomeric sleeve can power a blue light‐emitting diode and strain‐sensing circuit. These demonstrations suggest that stretchable EGaIn‐MnO₂ batteries are feasible for applications in wearable energy‐storage electronics.     

An Upgraded Lithium Ion Battery Based on a Polymeric Separator Incorporated with Anode Active Materials

Structural/compositional characteristics at the anode/electrolyte interface are of paramount importance for the practical performance of lithium ion batteries, including cyclic stability, rate capacity, and operational safety. The anode‐electrolyte interface with traditional separator technology is featured with inevitable phase discontinuity and fails to support the stable operation of lithium ion batteries based on large‐capacity anodes with structural change in charges/discharges, such as transition metal oxide anodes. In this work, an anode/electrolyte framework based on an oxide anode and an active‐oxide‐incorporated separator is proposed for the first time and investigated for lithium ion batteries. The architecture builds a robust anode‐separator interface in LIBs, shortens Li⁺ diffusion path, accelerates electron transport, and mitigates the volume change of the oxide anode in electrochemical reactions. Remarkably, 4 wt% CuO addition in the separator leads to a 17% enhancement in the overall capacity of a battery with a CuO anode. The battery delivers an unparalleled record reversible capacity of 637.2 mAh g^?1 with a 99% capacity retention after 100 charge/discharge cycles at 0.5 C. The high performance are attributed to the robust anode‐separator interface, which gives rise to enhanced interaction between the oxide anode and the same‐oxide‐incorporated composite in the separator.     

Stable Li–Organic Batteries with Nafion‐Based Sandwich‐Type Separators

Similar to Li–S batteries, Li–organic batteries have also been plagued by the dissolution of active materials and the resulting shuttle effect for many years. An effective strategy to eliminate the shuttle effect is adopting solid electrolytes or Li–ion permselective separators to prohibit the dissolved electroactive species from migrating to the Li anode. A polypropylene/Nafion/polypropylene (PNP) sandwich‐type separator is reported with many advantages in comparison with previously reported LISICON, polymer electrolyte, and other Nafion utilization forms. The physical and chemical properties of PNP separators are studied in detail by cross‐section scanning electron microscopy (SEM), infrared spectroscopy (IR), and electrochemical impedance spectroscopy. 1,1′‐Iminodianthraquinone (IDAQ), a novel organic cathode, is taken as an example to quantitatively investigate the function of PNP separators. In the presence of PNP5 with the most appropriate Nafion loading of 0.5 mg cm^–2, IDAQ is able to achieve dramatically improved cycling stability with capacity retention of 76% after 400 cycles and Coulombic efficiency above 99.6%, which reaches the highest level for reported soluble organic electrode materials. Besides Li–organic batteries, such kind of Nafion‐based sandwich‐type separators are also promising for Li–S batteries and other new battery designs involving dissolved electroactive species.     

Jabuticaba‐Inspired Hybrid Carbon Filler/Polymer Electrode for Use in Highly Stretchable Aqueous Li‐Ion Batteries

Stretchable electronics are considered as next‐generation devices; however, to realize stretchable electronics, it is first necessary to develop a deformable energy device. Of the various components in energy devices, the fabrication of stretchable current collectors is crucial because they must be mechanically robust and have high electrical conductivity under deformation. In this study, the authors present a conductive polymer composite composed of Jabuticaba‐like hybrid carbon fillers containing carbon nanotubes and carbon black in a simple solution process. The hybrid carbon/polymer (HCP) composite is found to effectively retain its electrical conductivity, even when under high strain of ≈200%. To understand the behavior of conductive fillers in the polymer matrix when under mechanical strain, the authors investigate the microstructure of the composite using an in situ small‐angle X‐ray scattering analysis. The authors observe that the HCP produces efficient electrical pathways for filler interconnections upon stretching. The authors develop a stretchable aqueous rechargeable lithium‐ion battery (ARLB) that utilizes this HCP composite as a stretchable current collector. The ARLB exhibits excellent rate capability (≈90 mA h g^?1 at a rate of 20 C) and outstanding capacity retention of 93% after 500 cycles. Moreover, the stretchable ARLB is able to efficiently deliver power even when under 100% strain.     

Enabling Deformable and Stretchable Batteries

Deformable energy storage devices are needed to power next‐generation wearable electronics that interface intimately with human skin. Currently, deformable energy storage devices demonstrate poor performance compared to their rigid lithium‐ion counterparts, forcing wearable manufacturers to design their devices around bulky battery compartments. However, technological advances to create deformable batteries at the component and device level have yielded continuous improvement in stretchable batteries over the last five years. In this Essay, the major strategies at the component and device level that have been successfully employed to create stretchable batteries are reviewed. The outstanding challenges facing deformable energy storage are also discussed, namely, energy density, packaging, delamination, device integration, and manufacturing. This Essay will give researchers who are interested in contributing to the development of deformable batteries a cursory understanding of the most successful strategies to date, and provide insights into the most important directions to pursue in the future.     

Multifunctional Manganese Ions Trapping and Hydrofluoric Acid Scavenging Separator for Lithium Ion Batteries Based on Poly(ethylene‐alternate‐maleic acid) Dilithium Salt

Manganese dissolution from positive electrodes seriously reduces the life of Li‐ion batteries, due to its detrimental impact on the passivation of negative electrodes. A novel multifunctional separator incorporating inexpensive mass‐produced polymeric materials may dramatically increases the durability of Li‐ion batteries. The separator is made by embedding the poly(ethylene‐alternate‐maleic acid) dilithium salt polymer into a poly(vinylidene fluoride‐hexafluoropropylene) copolymer matrix. LiMn₂O₄‐graphite cells comprising a 1 m LiPF₆ solution in ethylene carbonate plus dimethyl carbonate (1:1 v/v) and the functional separator retain 31% and 100% more capacity than baseline cells with plain commercial separators after 100 cycles at C/5 rate, respectively, at 30 and 55 °C. Analyses of cycled cells indicate greatly reduced Mn contamination of the graphite negative electrodes and almost no irreversible structural change in the LiMn₂O₄ positive electrodes from cells containing the functional separator. The Mn amount in the graphite electrodes from cycled cells with functional separators is ≈80% lower than in the graphite electrodes from cycled baseline cells. Mn ions are found in the functional separators but not in baseline (plain) separators from cycled cells. Finally, it is shown that the reported performance improvements stem from the ability of the novel separator to chelate Mn ions and to scavenge trace HF.     

A Multifunctional Separator Enables Safe and Durable Lithium/Magnesium–Sulfur Batteries under Elevated Temperature

Rechargeable metal–sulfur batteries encounter severe safety hazards and fast capacity decay, caused by the flammable and shrinkable separator and unwanted polysulfide dissolution under elevated temperatures. Herein, a multifunctional Janus separator is designed by integrating temperature endurable electrospinning polyimide nonwovens with a copper nanowire‐graphene nanosheet functional layer and a rigid lithium lanthanum zirconium oxide‐polyethylene oxide matrix. Such architecture offers multifold advantages: i) intrinsically high dimensional stability and flame‐retardant capability, ii) excellent electrolyte wettability and effective metal dendritic growth inhibition, and iii) powerful physical blockage/chemical anchoring capability for the shuttled polysulfides. As a consequence, the as constructed lithium–sulfur battery using a pure sulfur cathode displays an outstandingly high discharge capacity of 1402.1 mAh g^?1 and a record high cycling stability (approximately average 0.24% capacity decay per cycle within 300 cycles) at 80 °C, outperforming the state‐of‐the‐art results in the literature. Promisingly, a high sulfur mass loading of ≈3.0 mg cm^?2 and a record low electrolyte/sulfur ratio of 6.0 are achieved. This functional separator also performs well for a high temperature magnesium–sulfur battery. This work demonstrates a new concept for high performance metal–sulfur battery design and promises safe and durable operation of the next generation energy storage systems.     

Highly Stretchable,Sparse, Metallized Nanofiber Webs as Thin,Transferrable Transparent Conductors

The need for transparent conductors (TCs) that are capable of withstanding high mechanical deformation in comparison to the brittle indium tin oxide (ITO) films is paramount for roll‐to‐roll production of flexible and stretchable displays, signage systems, lighting devices and solar panels with stringent weatherability requirements. This paper reports a highly stretchable TC comprising of a web of core‐shell nanofibers, which mimics the fibrous structure of natural systems such as veins of a leaf or nerve systems. The TC web demonstrates high transparency, low sheet resistance, and unprecedented stretchability and stability over repeated stretching. The nanofiber TC web can be transferred to different substrates, which is manifested by the transfer onto an organic solar cell, demonstrating a photovoltaic performance comparable to that of a device with an ITO electrode. This work presents a technological platform, scalable for the manufacturing of large area transparent conductors for flexible and stretchable displays, electronics and solar cells on unconventional substrates such as rubber, fabric and paper.     

Polyester Separators for Lithium‐Ion Cells: Improving Thermal Stability and Abuse Tolerance

This report describes the preparation and performance of electro‐spun polyester‐based separators for lithium‐ion batteries. Polyester fibers (200–500 nm) are electro‐spun into nonwoven mats and pressed into separator sheets ～55 μm thick. The resulting polyester separators are 75% porous, highly permeable (Gurley number (s/100 mL) = 6), and have good wettability with conventional carbonate‐based electrolyte. In NMC/graphite lithium‐ion cells, results show comparable performance to commercially available polyolefin separators (rate, capacity fade, and reactivity) but with improved thermal stability to >200 °C. The use of this higher melting temperature polymer separator is one approach to close the gap between potential thermal instabilities (softening, shrinking, melting, etc.) of separators and the onset of thermal runaway reactions of commonly used cathode materials.     

An Efficient Separator with Low Li‐Ion Diffusion Energy Barrier Resolving Feeble Conductivity for Practical Lithium–Sulfur Batteries

Due to unprecedented features including high‐energy density, low cost, and light weight, lithium–sulfur batteries have been proposed as a promising successor of lithium‐ion batteries. However, unresolved detrimental low Li‐ion transport rates in traditional carbon materials lead to large energy barrier in high sulfur loading batteries, which prevents the lithium–sulfur batteries from commercialization. In this report, to overcome the challenge of increasing both the cycling stability and areal capacity, a metallic oxide composite (NiCo₂O₄@rGO) is designed to enable a robust separator with low energy barrier for Li‐ion diffusion and simultaneously provide abundant active sites for the catalytic conversion of the polar polysulfides. With a high sulfur‐loading of 6 mg cm^?2 and low sulfur/electrolyte ratio of 10, the assembled batteries deliver an initial capacity of 5.04 mAh cm^?2 as well as capacity retention of 92% after 400 cycles. The metallic oxide composite NiCo₂O₄@rGO/PP separator with low Li‐ion diffusion energy barrier opens up the opportunity for lithium–sulfur batteries to achieve long‐cycle, cost‐effective operation toward wide applications in electric vehicles and electronic devices.     

Electrochemically Stable Rechargeable Lithium–Sulfur Batteries with a Microporous Carbon Nanofiber Filter for Polysulfide

As a primary component in lithium–sulfur (Li–S) batteries, the separator may require a custom design in order to facilitate electrochemical stability and reversibility. Here, a custom separator with an activated carbon nanofiber (ACNF)‐filter coated onto a polypropylene membrane is presented. The entire configuration is comprised of the ACNF filter arranged adjacent to the sulfur cathode so that it can filter out the freely migrating polysulfides and suppress the severe polysulfide diffusion. Four differently optimized ACNF‐filter‐coated separators have been developed with tunable micropores as an investigation into the electrochemical and engineering design parameters of functionalized separators. The optimized parameters that are verified by electrochemical and microstructural analyses require the coated ACNF filter to possess the following: (i) a porous architecture with abundant micropores, (ii) small micropore sizes, and (iii) high electrical conductivity and effective electrolyte immersion. It is found that the ACNF20‐filter‐coated separator demonstrates an overall superior boost in the electrochemical utilization (discharge capacity: 1270 mA h g^?1) and polysulfide retention (capacity fade rate: 0.13% cycle^?1 after 200 cycles). These results show that the modified thin‐film‐coating technique is a viable approach to designing ultratough ACNF‐filter‐coated separators with outstanding mechanical strength and flexibility as an advanced component in Li–S cells.