Polyolefin separators are widely used in commercial lithium-ion batteries (LIBs), but their inherent limitations, such as poor thermal stability and low electrolyte wettability, restrict the further improvement of LIB performance. This paper presents a novel process for recovering and preparing submicron level AlOOH (boehmite) from the waste liquid of aluminum electrolytic capacitors. In addition, AlOOH/PVP@PP composite separators were prepared by utilizing polyvinylpyrrolidone (PVP), which has high thermal stability, as a binder, which significantly improves the thermal stability and electrochemical performance of lithium-ion batteries. The results of the study showed that the incorporation of polyvinylpyrrolidone (PVP) binder and AlOOH greatly improved the thermal stability of polypropylene (PP) separators. The thermal shrinkage of the AlOOH/PVP@PP separator at 180 °C was significantly reduced from 10.1% to 1.5% compared to the AlOOH/PVDF@PP separator fabricated with the conventional binder, while the structure of the AlOOH coating remained unchanged without significant changes. In addition, the voids between the AlOOH particles in the coating help to improve the containment of the electrolyte, which significantly improves the wettability of the separator. More importantly, the strong polarity of the PVP binder enhances the wettability of the separator to the electrolyte, improves the lithium-ion migration efficiency in the AlOOH/PVP@PP separator, and raises the ion transfer number from 0.447 to 0.661, thereby improving the electrochemical performance of the battery.
Graphical Abstract
This study leveraged the waste liquid from aluminum electrolytic capacitors to synthesize submicron-sized boehmite (AlOOH). It further employed PVP-a thermally stable binder with strong adhesion to both PP and AlOOH-to fabricate the AlOOH/PVP@PP composite separator. This innovative composite separator substantially enhanced the safety and electrochemical performance of the battery.