Abstract: An optimized electrochemical cell comprised of a housing divided into two chambers, a first chamber containing a protogenous, ion-conducting liquid and a positive high density electrode including a first active material and a porous binder, surrounded by a surface in which the porosity level increases towards the surface, a second chamber containing an aprotic, ion conducting liquid and a negative high density electrode including a second active material and a porous binder, surrounded by a surface in which the porosity level increases towards the surface. A symmetric, strong, highly porous, microporous polymer membrane divides the housing into the first and second chamber. The porosity level of the polymer membrane is 25% greater than the porosity level at the surface of the positive and negative high density electrodes.

Abstract: A battery separator may be formed with hard spacers made from ceramic and other high temperature materials. The spacers may be incorporated into a microporous membrane so that the microporous matrix may capture and hold the spacers. The spacers may be solid or hollow glass beads that are in the range of 30% to 100% of the thickness of the separator, and may comprise less than 10 weight percent. The resulting membrane may be largely microporous, and the separators may help battery electrodes to remain physically separated, even after internal temperatures exceed the melt temperature of the separator.

Abstract: A microporous polymer used as a battery separator may be formed with hard, insoluble dielectric spacer materials in fibrous or particulate form. The spacer materials may form a barrier when the battery separator may melt or be crushed during an over-temperature event, possibly preventing a fire. The spacer materials may be located within the polymer matrix and may be added to a solution used to form the microporous polymer.

Abstract: Bedding products may utilize unique microporous films imparting bidirectional, micro particle and fluid penetration barrier properties, which may or may not contain active ingredient, while maintaining exceptional air permeability. A thin, microporous film with a unique sponge like cellular structure may prevent the migration of dust mites, dust mite feces, other micro particle allergens, pathogens and biological organisms from the interstices of the product to the sleep surface of the product, adversely affecting user health and comfort. Active ingredients such as anti microbial agents, metal oxides, and other materials may be used within the high capacity microporous structure of the film, and may provide customizable functionalities while maintaining barrier performance and superior air permeability. The micro structured film can be applied as a coating or a laminate to mattress or pillow ticking, a foam mattress construction, a comforter, duvet, mattress pad and/or other components of bedding products.

Abstract: A microporous fire resistant film coated or laminated composite textile may be uses as an upholstery fabric or mattress ticking which provides an air permeable microporous barrier to liquid, allergen or pathogen particle, or biological organism penetration. The microporous cellular structure of the coated or laminated film backing may provide a high capacity reservoir which may contain additives such as antimicrobial, UV absorbing, scent dispersing, or organism repelling particles or other functional agents, while maintaining superior barrier and air permeability properties in the finished product constructions. Applications may include any seating and bedding products where a combination of two or more of the above properties is desired.

Abstract: A barrier membrane for use in building construction may be manufactured by forming a polymeric film coating on release paper or film; or on nonwoven textiles, paper, fiberglass, or other structural substrate to improve tensile strength. Alternatively, the film may be fully or partially formed and then bonded to a structural substrate. A porous film coating or laminate may be formed using PVDF, PVC, and various polyolefins. A typical membrane may be less than 100 mil thick and greater than 50% porous, and may have a hydrostatic head while retaining gas permeability. Some embodiments may contain active ingredients to combat bacterial or fungal growth, repel insects, or absorb environmental pathogens. The active ingredients may be applied after the porous film is manufactured or may be incorporated during the film manufacturing process.

Abstract: A novel electrolyte system technology, based on a supercritical fluid solvent using any of a variety of conventional dissolved species with organic salts, hydrates and aqueous-based systems being preferred, that is useful in a variety of electrochemical applications, including batteries, capacitors, fuel cells, sensors, fusion reactors and other similar types of electrolytic cells.

Abstract: A porous material manufactured Polyvinylidene Difluoride, or PVDF may be used in several configurations as a separator material for Lithium Ion and other types of batteries. The PVDF separator may be used with electrodes manufactured from a PVDF substrate for various lamination techniques in various configurations. The PVDF separator may be used in several configurations to enable more active material into a given battery construction, ensure better adhesion between layers, and overall increase the performance and capacity of a battery.

Abstract: An optimized electrochemical cell comprised of a housing divided into two chambers, a first chamber containing a protogenous, ion-conducting liquid and a positive high density electrode including a first active material and a porous binder, surrounded by a surface in which the porosity level increases towards the surface, a second chamber containing an aprotic, ion conducting liquid and a negative high density electrode including a second active material and a porous binder, surrounded by a surface in which the porosity level increases towards the surface. A symmetric, strong, highly porous, microporous polymer membrane divides the housing into the first and second chamber. The porosity level of the polymer membrane is 25% greater than the porosity level at the surface of the positive and negative high density electrodes.

Abstract: The present invention is directed to methods of producing a symmetric, strong, highly porous, microporous polymer film by (a) forming a layer of a polymer solution on a substrate, the solution comprising two miscible liquids and a polymer material dissolved therein, and wherein the first liquid has a surface tension lower than the surface energy of the polymer and the second liquid has a surface tension greater than the surface energy of the polymer; (b) producing a film of gelled polymer from the layer of polymer solution; and (c) rapidly removing the liquid from the film of gelled polymer by unidirectional mass transfer without dissolving the gelled polymer.

Abstract: The present invention provides microporous polymers and methods for producing and using the same. In particular, microporous polymers of the present invention are highly porous as indicated by a Gurley air permeability flow rate of about 4 seconds or less per mL of air flow per 25 micron of microporous polymer thickness per square inch.