In Situ Thermal Safety Aspect of the Electrospun Polyimide-Al₂O₃ Separator Reveals Less Exothermic Heat Energies Than Polypropylene at the Thermal Runaway Event of Lithium-Ion Batteries

Polyimide-Al2O3 membranes are developed as a direct alternative to current polyolefin separators by the electrospinning technique and their chemical structures confirm the carbonyl group with the presence of asymmetric and symmetric stretching and bending vibrations at 1778, 1720, and 720 cm–1 and stretching vibration at 1373 cm–1 for the imide group. Porous nanofiber architecture morphology is realized with a nanofiber thickness of ∼200 nm and shows an ultrasmooth surface and >1 μm pore size in the architecture, built with the chemical constituents of carbon, nitrogen, aluminum, and oxygen elements. The galvanostatic cycling study of the Li/PI-Al2O3/LiFePO4 lithium cell delivers stable charge–discharge capacities of 144/143 mAh g–1 at 0.2 C and 110/100 mAh g–1 at 1 C for 1–100 cycles. The fabricated MCMB/PI-Al2O3/LiFePO4 lithium-ion full-cell reveals less charge transfer resistance of Rct ∼ 25 Ω and yields stable charge–discharge capacities of 125/119 mAh g–1. The thermogravimetric curve for the PI-Al2O3 separator discloses thermal stability up to 525 °C, and the differential scanning calorimetric curve shows a straight line until 300 °C and depicts high thermal stability than the PP separator. In situ multimode calorimetry analysis of the MCMB/PP/LiFePO4 full-cell showed a pronounced exothermic peak at 225 °C with a higher released heat energy of 211 J g–1 at the thermal runaway event, while the MCMB/PI-Al2O3/LiFePO4 full-cell revealed an almost 8-fold less exothermic released heat energy of 25 J g–1 than the Celgard polypropylene separator, which was because the MCMB anode and LiFePO4 cathode can be mechanically isolated without any additional separator’s melting and burning reactions, as a fire-suppressant separator for lithium-ion batteries.