To address the poor thermomechanical stability and strong hydrophobicity of commercial polypropylene (PP) separators in lithium-ion batteries (LIBs), this study prepared functionalized PP-based separators via melt blending and UV-induced crosslinking. Carbazole-functionalized PP (PPCZ) was incorporated into the PP matrix, and a thermally stable 3D covalent network was constructed through in-situ self-crosslinking of carbazole groups under 365 nm UV irradiation. The synthesis of carbazole monomer UDK was optimized using KOH as a deprotonating agent instead of K2CO3, increasing monomer yield to 92 % with a reaction rate improvement of 30 % and simplifying purification. Metallocene-catalyzed copolymerization of UDK and propylene yielded PPCZ with 1.5 mol% carbazole insertion and a number-average molecular weight of approximately 90,000, and the product showed excellent PP matrix compatibility without phase separation. Key tests demonstrated that the 10 wt% PPCZ separator delivered superior comprehensive performance. Its thermal shrinkage at 105 °C measured 12 %, in sharp contrast to 28 % for the pristine PP separator and 18 % for the commercial Al₂O₃-coated PP separator. The temperature corresponding to 5 % weight loss (T5) hit 342.2 °C, representing a 3.7 °C increase over pristine PP. Meanwhile, electrolyte wettability was significantly enhanced, with the contact angle reduced to 75° as opposed to 98° for pure PP. Despite slight decreases in porosity from 39.5 % to 36.8 %, electrolyte absorption from 120 % to 115 %, crystallinity from 51.1 % to 43.8 %, and ionic conductivity from 0.19 to 0.14 mS·cm−1, the separator achieved an optimal balance of thermomechanical stability, wettability, and mechanical properties with a tensile strength of 110 MPa, puncture strength of 850 gf and elongation at break of 128 %, thus avoiding embrittlement. The strategy is compatible with existing dry-process lines, avoids ceramic coating issues such as high cost and delamination, and shows great potential for high-safety LIBs.
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