Electrospun polyacrylonitrile nanofibrous membranes with varied fiber diameters and different membrane porosities as lithium-ion battery separators

Highlights: • Nine types of electrospun polyacrylonitrile nanofibrous membranes were prepared. • These membranes had varied fiber diameters and different membrane porosities. • The membranes were explored as innovative Li-ion battery (LIB) separators. • The hot-pressed membrane with thin fibers had superior performance as LIB separator. - Abstract: In this study, nine types of polyacrylonitrile (PAN) nanofibrous membranes with varied fiber diameters and different membrane porosities are prepared by electrospinning followed by hot-pressing. Subsequently, these membranes are explored as Li-ion battery (LIB) separators. The impacts of fiber diameter and membrane porosity on electrolyte uptake, Li⁺ ion transport through the membrane, electrochemical oxidation potential, and membrane performance as LIB separator (during charge/discharge cycling and rate capability tests of a cathodic half-cell) have been investigated. When compared to commercial Celgard PP separator, hot-pressed electrospun PAN nanofibrous membranes exhibit larger electrolyte uptake, higher thermal stability, wider electrochemical potential window, higher Li⁺ ion permeability, and better electrochemical performance in LiMn₂O₄/separator/Li half-cell. The results also indicate that the PAN-based membrane/separator with small fiber diameters of 200–300 nm and hot-pressed under high pressure of 20 MPa surpasses all other membranes/separators and demonstrates the best performance, leading to the highest discharge capacity (89.5 mA h g⁻¹ at C/2 rate) and cycle life (with capacity retention ratio being 97.7%) of the half-cell. In summary, this study has revealed that the hot-pressed electrospun PAN nanofibrous membranes (particularly those consisting of thin nanofibers) are promising as high-performance LIB separators.