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By preventing electrical contact between anode and cathode electrodes while promoting ionic transport, separators are critical components in the safe operation of rechargeable battery technologies. However, traditional polymer-based separators have limited thermal stability, which has contributed to catastrophic thermal runaway failure modes that have conspicuously plagued lithium-ion batteries. Here, we describe the development of phase-inversion composite separators based on carbon-coated hexagonal boron nitride (hBN) nanosheets and poly(vinylidene fluoride) (PVDF) polymers that possess high porosity, electrolyte wettability, and thermal stability. The carbon-coated hBN nanosheets are obtained through a scalable liquid-phase shear exfoliation method using ethyl cellulose as a polymer stabilizer and source of the carbon coating following thermal pyrolysis. When incorporated within the PVDF matrix, the carbon-coated hBN nanosheets promote favorable interfacial interactions during the phase-inversion process, resulting in porous, flexible, free-standing composite separators. The unique chemical composition of these carbon-coated hBN separators implies high wettability for a wide range of liquid electrolytes. This combination of high porosity and electrolyte wettability enables enhanced ionic conductivity and lithium-ion battery electrochemical performance that exceeds incumbent polyolefin separators over a wide range of operating conditions. The hBN nanosheets also impart high thermal stability, providing safe lithium-ion battery operation up to 120 °C.

A combined study involving experiments and multiscale computational approaches is conducted to propose a theoretical solution for the suppression of the Jahn-Teller distortion which causes severe cyclic degradation. As-synthesized pristine and Al-doped Mn spinel compounds are the focus to understand the mechanism of the cyclic degradation in terms of the Jahn-Teller distortion, and the electrochemical performance of the Al-doped sample shows enhanced cyclic performance compared with that of the pristine one. Considering the electronic structures of the two systems using first-principles calculations, the pristine spinel suffers entirely from the Jahn-Teller distortion by Mn(3+), indicating an anisotropic electronic structure, but the Al-doped spinel exhibits an isotropic electronic structure, which means the suppressed Jahn-Teller distortion. A multiscale phase field model in nanodomain shows that the phase separation of the pristine spinel occurs to inactive Li0Mn2O4 (i.e., fully delithiated) gradually during cycles. In contrast, the Al-doped spinel does not show phase separation to an inactive phase. This explains why the Al-doped spinel maintains the capacity of the first charge during the subsequent cycles. On the basis of the mechanistic understanding of the origins and mechanism of the suppression of the Jahn-Teller distortion, fundamental insight for making tremendous cuts in the cyclic degradation could be provided for the Li-Mn-O compounds of Li-ion batteries.