Three-Dimensional Ordered Porous SnO2 Nanostructures Derived from Polystyrene Sphere Templates for Ethyl Methyl Carbonate Detection in Battery Safety Applications Cao, Peijiang Qu, Linlong Jia, Fang Zeng, Yuxiang Zhu, Deliang Wang, Chunfeng Han, Shun Fang, Ming Liu, Xinke Liu, Wenjun T. Navale, Sachin battery safety electrolyte leakage ordered porous SnO2 nanostructures gas sensor EMC detection As lithium-ion batteries (LIBs) gain widespread use, detecting electrolyte–vapor emissions during early thermal runaway (TR) remains critical to ensuring battery safety; yet, it remains understudied. Gas sensors integrating oxide nanostructures offer a promising solution as they possess high sensitivity and fast response, enabling rapid detection of various gas-phase indicators of battery failure. Utilizing this approach, 3D ordered tin oxide (SnO2) nanostructures were synthesized using polystyrene sphere (PS) templates of varied diameters (200–1500 nm) and precursor concentrations (0.2–0.6 mol/L) to detect key electrolyte–vapors, especially ethyl methyl carbonate (EMC), released in the early stages of TR. The 3D ordered SnO2 nanostructures with ring- and nanonet-like morphologies, formed after PS template removal, were characterized, and the effects of template size and precursor concentration on their structure and sensing performance were investigated. Among various nanostructures of SnO2, nanonets achieved by a 1000 nm PS template and 0.4 mol/L precursor showed higher mesoporosity (~28 nm) and optimal EMC detection. At 210 ◦C, it detected 10 ppm EMC with a response of ~7.95 and response/recovery times of 14/17 s, achieving a 500 ppb detection limit alongside excellent reproducibility/stability. This study demonstrates that precise structural control of SnO2 nanostructures using templates enables sensitive EMC detection, providing an effective sensor-based strategy to enhance LIB safety. 2025-09-10T10:14:51Z 2025-09-10T10:14:51Z 2025-07-25 journal article Cao, P.; Qu, L.; Jia, F.; Zeng, Y.; Zhu, D.; Wang, C.; Han, S.; Fang, M.; Liu, X.; Liu, W.; et al. ThreeDimensional Ordered Porous SnO2 Nanostructures Derived from Polystyrene Sphere Templates for Ethyl Methyl Carbonate Detection in Battery Safety Applications. Nanomaterials 2025, 15, 1150. https://doi.org/10.3390/nano15151150 https://hdl.handle.net/10481/106219 10.3390/nano15151150 eng http://creativecommons.org/licenses/by/4.0/ open access Atribución 4.0 Internacional MDPI