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Roll-to-roll fabricated polymer composites filled with subnanosheets exhibiting high energy density and cyclic stability at 200 °C

Nature Energy volume 9, pages 143–153 (2024)Cite this article

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Abstract

Polymers are key dielectric media for energy storage capacitors in power electronics for electric vehicles and solar panels, and there is an urgent need to enhance their discharged energy density (Ud) at high temperatures. Existing polymer–inorganic nanocomposites with high Ud cannot be produced by conventional roll-to-roll fabrication processes and exhibit compromised cyclic stability. In this study, we introduced phosphotungstic acid subnanosheets, a ‘reservoir’ for charges, into polymers to form a subnanocomposite. Even a low loading (0.2 wt%) of ultralarge, ultrathin, flexible subnanosheets was found to effectively strengthen polymers and hinder the propagation of breakdown paths. These subnanosheets can also trap charges through grafted surfactant molecules and polyoxometalate cluster backbones. An ultrahigh Ud of 7.2 J cm−3 with a charge–discharge efficiency of 90% and charge–discharge cycle stability up to 5 × 105 cycles at 200 °C were observed. Furthermore, a 100-metre-long roll of the subnanocomposite film was roll-to-roll fabricated on an industrial solution-casting production line. This work demonstrates the potential of this subnanocomposite strategy for the mass fabrication and application of high-performance polymer dielectrics.

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Fig. 1: Characterization of PWNSs and polymer–PWNS subnanocomposites.
Fig. 2: Mechanical strengthening and breakdown path hindrance of the PWNSs.
Fig. 3: Charge trapping and improved energy storage performance of the PWNSs.
Fig. 4: Reliability and industrial preparation of polymer–PWNS subnanocomposites.

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The data supporting the findings of this study are available in this article and its Supplementary Information. Source data are provided with this paper.

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Acknowledgements

This work was supported by the National Natural Science Foundation of China (grant nos. 52388201 (C.-W.N.), 52027817 (Y.S.), 52002207 (W.R.), 92261118 (W.S.), 22241502 (X.W.), 22250710677 (X.W.) and 22035004 (X.W.)).

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Author notes

  1. These authors contributed equally: Minzheng Yang, Haoyang Li.

Authors and Affiliations

  1. School of Materials Science and Engineering, State Key Laboratory of New Ceramics and Fine Processing, Tsinghua University, Beijing, China

    Minzheng Yang, Weibin Ren, Mengfan Guo, Erxiang Xu, Nannan Sun, Le Zhou, Yao Xiao, Mufeng Zhang, Ce-Wen Nan & Yang Shen

  2. Department of Chemistry, Engineering Research Center of Advanced Rare Earth Materials, Tsinghua University, Beijing, China

    Haoyang Li, Zhong Li & Xun Wang

  3. State Key Laboratory of Advanced Technology for Materials Synthesis and Processing, Center of Smart Materials and Devices, Wuhan University of Technology, Wuhan, China

    Jian Wang & Zhonghui Shen

  4. School of Materials Science and Engineering, Institute for New Energy Materials and Low Carbon Technologies, Tianjin University of Technology, Tianjin, China

    Wenxiong Shi

  5. Beijing National Laboratory for Condensed Matter Physics, Institute of Physics, Chinese Academy of Sciences, Beijing, China

    Qinghua Zhang

  6. Center for Advanced Mechanics and Materials, Applied Mechanics Laboratory, Department of Engineering Mechanics, Tsinghua University, Beijing, China

    Hanzheng Xing & Xiaoyan Li

  7. Research Center for New Functional Composites, Wuzhen Laboratory, Tongxiang, China

    Binzhou Sun, Jiayu Pan & Jianyong Jiang

  8. National Center of Electron Microscopy in Beijing, School of Materials Science and Engineering, Tsinghua University, Beijing, China

    Lin Gu

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Contributions

M.Y., X.W. and Y.S. conceived the idea. M.Y. performed the majority of the experiments. H.L. and Z.L. synthesized and characterized the PWNS. J.W. performed the phase-field simulations under the supervision of Z.S. W.S. performed the molecular dynamics simulations. Q.Z and L.G. performed the EELS characterizations. H.X. performed the finite element simulations under the supervision of X.L. W.R. and M.Z. assisted in the sample preparation and performance tests. N.S. assisted in the fitting and analysis of TSDC data. M.G. and L.Z. assisted in the data analysis and writing of the paper. Y.X. prepared the TEM samples. E.X. performed the SKPM characterizations. B.S., J.P. and J.J. prepared the large-scale film samples. C.-W.N., X.W. and Y.S. supervised the whole project.

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Correspondence to Xun Wang or Yang Shen.

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Nature Energy thanks Alamgir Karim, Qing Wang and Haixue Yan for their contribution to the peer review of this work.

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All data points in Fig. 4, and the raw data for the statistical analysis in Fig. 4g.

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Yang, M., Li, H., Wang, J. et al. Roll-to-roll fabricated polymer composites filled with subnanosheets exhibiting high energy density and cyclic stability at 200 °C. Nat Energy 9, 143–153 (2024). https://doi.org/10.1038/s41560-023-01416-3

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