Abstract: Described herein is a multilayer microporous film or membrane that may exhibit improved properties, including improved dielectric break down and strength, compared to prior monolayer or tri-layer microporous membranes of the same thickness. The preferred multilayer microporous membrane comprises microlayers and one or more lamination interfaces or barriers. Also disclosed is a battery separator or battery comprising one or more of the multilayer microporous films or membranes. The inventive battery and battery separator is preferably safer and more robust than batteries and battery separators using prior monolayer and tri-layer microporous membranes. Also, described herein is a method for making the multilayer microporous separators, membranes or films described herein.

Abstract: Described herein, are battery separators, comprising the following: a microporous polymeric film; and an optional coating layer on at least one side of the microporous polymeric film, wherein at least one of the microporous polymeric film and the optional coating comprises an additive. The additive is selected from the group consisting of a lubricating agent, a plasticizing agent, a nucleating agent, a shrinkage reducing agent, a surfactant, an SEI improving agent, a cathode protection agent, a flame retardant additive, LiPF6 salt stabilizer, an overcharge protector, an aluminum corrosion inhibitor, a lithium deposition agent or improver, or a solvation enhancer, an aluminum corrosion inhibitor, a wetting agent, and a viscosity improver. Also, described herein are batteries, including lithium-ion batteries, comprising one or more of the described separators. Methods for making the battery separators are also described.

Abstract: A coated battery separator is described herein. The coated battery separator includes a porous membrane with a coating on at least one side thereof, wherein the coated separator exhibits at least one of improved thickness uniformity of the coating and improved adhesion of the coating to the porous membrane. In some embodiments, the coated battery separator is thin or ultrathin. A method for forming a coated battery separator that exhibits the aforementioned properties is also described. The method may include steps of forming a coating and calendering the coating. In some embodiments, calendering is performed on a dried coating. In some embodiments, the coating is or includes a ceramic coating, a polymer coating, a sticky coating, a shutdown coating, or combinations thereof.

Abstract: Described herein, are battery separators, comprising the following: a microporous polymeric film; and an optional coating layer on at least one side of the microporous polymeric film, wherein at least one of the microporous polymeric film and the optional coating comprises an additive. The additive is selected from the group consisting of a lubricating agent, a plasticizing agent, a nucleating agent, a shrinkage reducing agent, a surfactant, an SEI improving agent, a cathode protection agent, a flame retardant additive, LiPF6 salt stabilizer, an overcharge protector, an aluminum corrosion inhibitor, a lithium deposition agent or improver, or a solvation enhancer, an aluminum corrosion inhibitor, a wetting agent, and a viscosity improver. Also, described herein are batteries, including lithium-ion batteries, comprising one or more of the described separators. Methods for making the battery separators are also described.

Abstract: In accordance with at least selected embodiments, novel or improved porous membranes or substrates, separator membranes, separators, composites, electrochemical devices, batteries, methods of making such membranes or substrates, separators, and/or batteries, and/or methods of using such membranes or substrates, separators and/or batteries are disclosed. In accordance with at least certain embodiments, novel or improved microporous membranes, battery separator membranes, separators, energy storage devices, batteries including such separators, methods of making such membranes, separators, and/or batteries, and/or methods of using such membranes, separators and/or batteries are disclosed. In accordance with at least certain selected embodiments, a separator for a battery which has an oxidation protective and binder-free deposition layer which is stable up to 5.2 volts or more, for example, up to 7 volts, in a battery is disclosed.

Abstract: Described herein, are battery separators, comprising the following: a microporous polymeric film; and an optional coating layer on at least one side of the microporous polymeric film, wherein at least one of the microporous polymeric film and the optional coating comprises an additive. The additive is selected from the group consisting of a lubricating agent, a plasticizing agent, a nucleating agent, a shrinkage reducing agent, a surfactant, an SEI improving agent, a cathode protection agent, a flame retardant additive, LiPF6 salt stabilizer, an overcharge protector, an aluminum corrosion inhibitor, a lithium deposition agent or improver, or a solvation enhancer, an aluminum corrosion inhibitor, a wetting agent, and a viscosity improver. Also, described herein are batteries, including lithium-ion batteries, comprising one or more of the described separators. Methods for making the battery separators are also described.

Abstract: A new or improved microporous monolayer, bilayer, trilayer, or multilayer membrane, separator membrane, separator, or coated separator is disclosed. The membrane is preferably made up of at least one resin or polymer and at least one additive. The additive may comprise at least one material that improves adhesion of the microporous membrane to a coating, including a polyaramid-containing coating and a PCS coating, or to a different material such as a metallic surface, including an electrode surface. Improvements in adhesion are based on comparisons to similar microporous membranes without the at least one additive. In some preferred embodiments, the at least one additive may comprise, consist of, or consist essentially of a functionalized polymer or the combination of a functionalized polymer and an elastomer. In some embodiments, the functional group of the functionalized polymer may be maleic anhydride (MAH).

Abstract: In accordance with at least selected embodiments, novel or improved porous membranes or substrates, separator membranes, separators, composites, electrochemical devices, batteries, methods of making such membranes or substrates, separators, and/or batteries, and/or methods of using such membranes or substrates, separators and/or batteries are disclosed. In accordance with at least certain embodiments, novel or improved microporous membranes, battery separator membranes, separators, energy storage devices, batteries including such separators, methods of making such membranes, separators, and/or batteries, and/or methods of using such membranes, separators and/or batteries are disclosed. In accordance with at least certain selected embodiments, a separator for a battery which has an oxidation protective and binder-free deposition layer which is stable up to 5.2 volts or more, for example, up to 7 volts, in a battery is disclosed.

Abstract: Described herein, are battery separators, comprising the following: a microporous polymeric film; and an optional coating layer on at least one side of the microporous polymeric film, wherein at least one of the microporous polymeric film and the optional coating comprises an additive. The additive is selected from the group consisting of a lubricating agent, a plasticizing agent, a nucleating agent, a shrinkage reducing agent, a surfactant, an SEI improving agent, a cathode protection agent, a flame retardant additive, LiPF6 salt stabilizer, an overcharge protector, an aluminum corrosion inhibitor, a lithium deposition agent or improver, or a solvation enhancer, an aluminum corrosion inhibitor, a wetting agent, and a viscosity improver. Also, described herein are batteries, including lithium-ion batteries, comprising one or more of the described separators. Methods for making the battery separators are also described.

Abstract: In accordance with at least selected embodiments, novel or improved porous membranes or substrates, separator membranes, separators, composites, electrochemical devices, batteries, methods of making such membranes or substrates, separators, and/or batteries, and/or methods of using such membranes or substrates, separators and/or batteries are disclosed. In accordance with at least certain embodiments, novel or improved microporous membranes, battery separator membranes, separators, energy storage devices, batteries including such separators, methods of making such membranes, separators, and/or batteries, and/or methods of using such membranes, separators and/or batteries are disclosed. In accordance with at least certain selected embodiments, a separator for a battery which has an oxidation protective and binder-free deposition layer which is stable up to 5.2 volts or more, for example, up to 7 volts, in a battery is disclosed.