Interfacial reaction-induced roughening in polymer thin films.

Reactive blending of immiscible polymers is an important process for synthesizing polymer blends with superior properties. We use a phase-field model to understand reaction dynamics and morphology evolution by diffusive transport in layered films of incompatible, end-reactive polymers. We thoroughly investigate this phenomenon over a large parameter space of interface shapes, layer thicknesses, reaction rates specified by a Damkohler number (Daf), and Flory-Huggins interaction parameter (χ), under static conditions with no external fields. For films of the same thickness, the dynamics of the system is not significantly influenced by the length of the film or the initial shape of the interface. The interface between the polymers is observed to roughen, leading to the formation of a spontaneous emulsion. The reaction progresses slower and the interface roughens later for thicker films, and systems with higher χ. Increasing Daf increases the reaction rate and hastens the onset of roughening. The quasi-static interfacial tension decreases with the extent of reaction, but does not become vanishingly small or negative at the onset of roughening. Simulations with reversible reactions and systems where only a fraction of the homopolymers have reactive end groups show that a critical diblock (reaction product) concentration exists, below which interfacial roughening and spontaneous emulsification is not observed. We also demonstrate that thermal fluctuations accelerate the onset of interfacial roughening, and help sustain the system in an emulsified state.

A phase field model for dynamic simulations of reactive blending of polymers.

A facile way to generate compatibilized blends of immiscible polymers is through reactive blending of end-functionalized homopolymers. The reaction may be reversible or irreversible depending on the end-groups and is affected by the immiscibility and transport of the reactant homopolymers and the compatibilizing copolymer product. Here we describe a phase-field framework to model the combined dynamics of reaction kinetics, diffusion, and multi-component thermodynamics on the evolution of the microstructure and reaction rate in reactive blending. A density functional with no fitting parameters, which is obtained by adapting a framework of Uneyama and Doi and qualitatively agrees with self-consistent field theory, is used in a diffusive dynamics model. For a symmetric mixture of equal-length reactive polymers mixed in equal proportions, we find that depending on the Flory χ parameter, the microstructure of an irreversibly reacting blend progresses through a rich evolution of morphologies, including from two-phase coexistence to a homogeneous mixture, or a two-phase to three-phase coexistence transitioning to a homogeneous blend or a lamellar copolymer. The emergence of a three-phase region at high χ leads to a previously unreported reaction rate scaling. For a reversible reaction, we find that the equilibrium composition is a function of both the equilibrium constant for the reaction and the χ parameter. We demonstrate that phase-field models are an effective way to understand the complex interplay of thermodynamic and kinetic effects in a reacting polymer blend.

Designing Polymeric Interphases for Stable Lithium Metal Deposition.

Reactive metals are known to electrodeposit with irregular morphological features on planar substrates. A growing body of work suggest that multiple variables: composition, mechanics, structure, ion transport properties, reductive stability, and interfacial energy of interphases, formed either spontaneously or by design on the metal electrode play important but differentiated roles in regulating these morphologies. We examine the effect of fluorinated thermoset polymer coatings on Li deposition by means of experiment and theoretical linear stability analysis. By tuning the chemistry of the polymer backbone and side chains, we investigate how physical and mechanical properties of polymeric interphases influence Li electrodeposit morphology. It is found that an interplay between elasticity and diffusivity leads to an optimum interphase thickness and that higher interfacial energy augments elastic stresses at a metal electrode to prevent out-of-plane deposition. These findings are explained using linear stability analysis of electrodeposition and provide guidelines for designing polymer interphases to stabilize metal anodes in rechargeable batteries.

Confining electrodeposition of metals in structured electrolytes.

Electrochemical cells based on alkali metal (Li, Na) anodes have attracted significant recent attention because of their promise for producing large increases in gravimetric energy density for energy storage in batteries. To facilitate stable, long-term operation of such cells a variety of structured electrolytes have been designed in different physical forms, ranging from soft polymer gels to hard ceramics, including nanoporous versions of these ceramics that host a liquid or molten polymer in their pores. In almost every case, the electrolytes are reported to be substantially more effective than anticipated by early theories in improving uniformity of deposition and lifetime of the metal anode. These observations have been speculated to reflect the effect of electrolyte structure in regulating ion transport to the metal electrolyte interface, thereby stabilizing metal electrodeposition processes at the anode. Here we create and study model structured electrolytes composed of covalently linked polymer grafted nanoparticles that host a liquid electrolyte in the pores. The electrolytes exist as freestanding membranes with effective pore size that can be systematically manipulated through straightforward control of the volume fraction of the nanoparticles. By means of physical analysis and direct visualization experiments we report that at current densities approaching the diffusion limit, there is a clear transition from unstable to stable electrodeposition at Li metal electrodes in membranes with average pore sizes below 500 nm. We show that this transition is consistent with expectations from a recent theoretical analysis that takes into account local coupling between stress and ion transport at metal-electrolyte interfaces.

Stabilizing electrochemical interfaces in viscoelastic liquid electrolytes.

Electrodeposition is a widely practiced method for creating metal, colloidal, and polymer coatings on conductive substrates. In the Newtonian liquid electrolytes typically used, the process is fundamentally unstable. The underlying instabilities have been linked to failure of microcircuits, dendrite formation on battery electrodes, and overlimiting conductance in ion-selective membranes. We report that viscoelastic electrolytes composed of semidilute solutions of very high-molecular weight neutral polymers suppress these instabilities by multiple mechanisms. The voltage window ΔV in which a liquid electrolyte can operate free of electroconvective instabilities is shown to be markedly extended in viscoelastic electrolytes and is a power-law function, ΔV : η1/4, of electrolyte viscosity, η. This power-law relation is replicated in the resistance to ion transport at liquid/solid interfaces. We discuss consequences of our observations and show that viscoelastic electrolytes enable stable electrodeposition of many metals, with the most profound effects observed for reactive metals, such as sodium and lithium. This finding is of contemporary interest for high-energy electrochemical energy storage.

Enthalpy-Driven Stabilization of Dispersions of Polymer-Grafted Nanoparticles in High-Molecular-Weight Polymer Melts.

Phase stability of polymer nanocomposites (PNCs) composed of polymer-grafted SiO2 nanoparticles (NPs) blended with high-molar-mass host polymer chains is investigated. We focus on blends in which the particle-grafted polymer, polyethylene glycol (PEG), and the host-atactic poly(methylmethacrylate) (PMMA) or PMMA/oligo-PEG blends-exhibit favorable enthalpic interactions. Small-angle X-ray scattering measurements are used to evaluate the phase stability of the blends and to report on the structure of the materials at intermediate and long length scales. By exploring SiO2-PEG/PMMA and SiO2-PEG/PMMA-PEG systems covering a wide range of molecular weights (Mw) of PMMA (1.1 kDa ≤ Mw,PMMA ≤ 1.1 × 103 kDa) and tethered PEG (0.5 kDa ≤ Mw, PEG ≤ 2 kDa), we are able to develop a comprehensive stability map for PNCs based on hairy NPs. At low Mw,PEG, the phase behavior is dominated by entropic effects and the negative Flory-Huggins χ parameter between PEG and PMMA plays no role in phase stability. For higher Mw,PEO and intermediate Mw,PMMA, a crossover from entropy- to enthalpy-dominated behavior is observed, which leads to the phase stability in PNCs well beyond the conventional limits reported for SiO2-PEG/PEG mixtures. This enhanced mixing ceases above a critical Mw,PMMA, where it is found that PMMA chains wet a sufficiently large number of SiO2-PEG particles to bridge and thereby destabilize the composites.

Stabilizing electrodeposition in elastic solid electrolytes containing immobilized anions.

Ion transport-driven instabilities in electrodeposition of metals that lead to morphological instabilities and dendrites are receiving renewed attention because mitigation strategies are needed for improving rechargeability and safety of lithium batteries. The growth rate of these morphological instabilities can be slowed by immobilizing a fraction of anions within the electrolyte to reduce the electric field at the metal electrode. We analyze the role of elastic deformation of the solid electrolyte with immobilized anions and present theory combining the roles of separator elasticity and modified transport to evaluate the factors affecting the stability of planar deposition over a wide range of current densities. We find that stable electrodeposition can be easily achieved even at relatively high current densities in electrolytes/separators with moderate polymer-like mechanical moduli, provided a small fraction of anions are immobilized in the separator.

Nanostructured electrolytes for stable lithium electrodeposition in secondary batteries.

Secondary batteries based on lithium are the most important energy storage technology for contemporary portable devices. The lithium ion battery (LIB) in widespread commercial use today is a compromise technology. It compromises high energy, high power, and design flexibility for long cell operating lifetimes and safety. Materials science, transport phenomena, and electrochemistry in the electrodes and electrolyte that constitute such batteries are areas of active study worldwide because significant improvements in storage capacity and cell lifetime are required to meet new demands, including the electrification of transportation and for powering emerging autonomous aircraft and robotics technologies. By replacing the carbonaceous host material used as the anode in an LIB with metallic lithium, rechargeable lithium metal batteries (LMBs) with higher storage capacity and compatibility with low-cost, high-energy, unlithiated cathodes such as sulfur, manganese dioxide, carbon dioxide, and oxygen become possible. Large-scale, commercial deployment of LMBs are today limited by safety concerns associated with unstable electrodeposition and lithium dendrite formation during cell recharge. LMBs are also limited by low cell operating lifetimes due to parasitic chemical reactions between the electrode and electrolyte. These concerns are greater in rechargeable batteries that utilize other, more earth abundant metals such as sodium and to some extent even aluminum. Inspired by early theoretical works, various strategies have been proposed for alleviating dendrite proliferation in LMBs. A commonly held view among these early studies is that a high modulus, solid-state electrolyte that facilitates fast ion transport, is nonflammable, and presents a strong-enough physical barrier to dendrite growth is a requirement for any commercial LMB. Unfortunately, poor room-temperature ionic conductivity, challenging processing, and the high cost of ceramic electrolytes that meet the modulus and stability requirements have to date proven to be insurmountable obstacles to progress. In this Account, we first review recent advances in continuum theory for dendrite growth and proliferation during metal electrodeposition. We show that the range of options for designing electrolytes and separators that stabilize electrodeposition is now substantially broader than one might imagine from previous literature accounts. In particular, separators designed at the nanoscale to constrain ion transport on length scales below a theory-defined cutoff, and structured electrolytes in which a fraction of anions are permanently immobilized to nanoparticles, to a polymer network or ceramic membrane are considered particularly promising for their ability to stabilize electrodeposition of lithium metal without compromising ionic conductivity or room temperature battery operation. We also review recent progress in designing surface passivation films for metallic lithium that facilitate fast deposition of lithium at the electrolyte/electrode interface and at the same time protect the lithium from parasitic side reactions with liquid electrolytes. A promising finding from both theory and experiment is that simple film-forming halide salt additives in a conventional liquid electrolyte can substantially extend the lifetime and safety of LMBs.