@Article{jpm.2025.062352,
AUTHOR = {Haoran Li, Yayou Xu, Zihan Zhang, Feng Han, Ye-Tang Pan, Rongjie Yang},
TITLE = {Advancements and Challenges in Enhancing Thermal Stability of Lithium-Ion Battery Separators: Review on Coating Materials, High-Temperature Resistant Materials and Future Trends},
JOURNAL = {Journal of Polymer Materials},
VOLUME = {42},
YEAR = {2025},
NUMBER = {1},
PAGES = {33--55},
URL = {http://www.techscience.com/jpm/v42n1/60177},
ISSN = {0976-3449},
ABSTRACT = {The thermal stability of lithium-ion battery separators is a critical determinant of battery safety and performance, especially in the context of rapidly expanding applications in electric vehicles and energy storage systems. While traditional polyolefin separators (PP/PE) dominate the market due to their cost-effectiveness and mechanical robustness, their inherent poor thermal stability poses significant safety risks under high-temperature conditions. This review provides a comprehensive analysis of recent advancements in enhancing separator thermal stability through coating materials (metal, ceramic, inorganic) and novel high-temperature-resistant polymers (e.g., PVDF copolymers, PI, PAN). Notably, we critically evaluate the trade-offs between thermal resilience and electrochemical performance, such as the unintended increase in electronic conductivity from metal coatings (e.g., Cu, MOFs) and reduced electrolyte wettability in ceramic coatings (e.g., Al<sub>2</sub>O<sub>3</sub>). Innovations in hybrid coatings (e.g., BN/PAN composites, gradient-structured MOFs) and scalable manufacturing techniques (e.g., roll-to-roll electrospinning) are highlighted as promising strategies to balance these competing demands. Furthermore, a comparative analysis of next-generation high-temperature-resistant separators underscores their ionic conductivity, mechanical strength, and scalability, offering actionable insights for material selection. The review concludes with forward-looking perspectives on integrating machine learning for material discovery, optimizing interfacial adhesion in ceramic coatings, and advancing semi-/all-solid-state batteries to address both thermal and electrochemical challenges. This work aims to bridge the gap between laboratory innovations and industrial applications, fostering safer and more efficient lithium battery technologies.},
DOI = {10.32604/jpm.2025.062352}
}