Abstract: The capability of directly gelling an electrolyte within a lithium ion (or similar type) battery cell through the reaction of the electrolyte solution with a present battery separator is provided. Such a procedure results generally from the presence of suitable nanofibers within the battery separator structure that exhibit the potential for swelling in the presence of a suitable electrolyte formulation. In this manner, the capability of providing an entrenched gel within the battery separator for longer term viability and electrical generation is possible without externally gelling the electrolyte prior to battery cell introduction. The method of use of such a resultant battery, as well as the battery including such an automatic gelling battery separator/electrolyte combination, are also encompassed within this invention.

Abstract: An insulating (nonconductive) microporous polymeric battery separator comprised of a single layer of enmeshed microfibers and nanofibers is provided. Such a separator accords the ability to attune the porosity and pore size to any desired level through a single nonwoven fabric. Through a proper selection of materials as well as production processes, the resultant battery separator exhibits isotropic strengths, low shrinkage, high wettability levels, and pore sizes related directly to layer thickness. The overall production method is highly efficient and yields a combination of polymeric nanofibers within a polymeric microfiber matrix and/or onto such a substrate through high shear processing that is cost effective as well. The separator, a battery including such a separator, the method of manufacturing such a separator, and the method of utilizing such a separator within a battery device, are all encompassed within this invention.

Abstract: An insulating (nonconductive) microporous nonwoven polymeric battery separator comprised of a single layer of enmeshed microfibers and nanofibers and supercalendered to extremely thin dimensions and high densities is provided. Such a separator accords the ability to not only attune the porosity and pore size to any desired level through a single nonwoven fabric, but provide further benefits in terms of further reduced pore size, reduced electrolyte level requirements, and reduced total volume of the subject battery cell itself. As a result, the inventive separator permits a high strength material with low porosity and low pore size to levels previously unattained. The separator, a battery including such a separator, the method of manufacturing such a separator, and the method of utilizing such a separator within a battery device, are all encompassed within this invention.

Abstract: An insulating (nonconductive) microporous polymeric battery separator comprised of a single layer of enmeshed microfibers and nanofibers is provided. Such a separator accords the ability to attune the porosity and pore size to any desired level through a single nonwoven fabric. Through a proper selection of materials as well as production processes, the resultant battery separator exhibits isotropic strengths, low shrinkage, high wettability levels, and pore sizes related directly to layer thickness. The overall production method is highly efficient and yields a combination of polymeric nanofibers within a polymeric microfiber matrix and/or onto such a substrate through high shear processing that is cost effective as well. The separator, a battery including such a separator, the method of manufacturing such a separator, and the method of utilizing such a separator within a battery device, are all encompassed within this invention.

Abstract: The capability of directly gelling an electrolyte within a lithium ion (or similar type) battery cell through the reaction of the electrolyte solution with a present battery separator is provided. Such a procedure results generally from the presence of suitable nanofibers within the battery separator structure that exhibit the potential for swelling in the presence of a suitable electrolyte formulation. In this manner, the capability of providing an entrenched gel within the battery separator for longer term viability and electrical generation is possible without externally gelling the electrolyte prior to battery cell introduction. The method of use of such a resultant battery, as well as the battery including such an automatic gelling battery separator/electrolyte combination, are also encompassed within this invention.

Abstract: The present invention relates to a microporous polymeric battery separator comprised of a single layer of enmeshed microfibers and nanofibers. Such a separator accords the ability to attune the porosity and pore size to any desired level through a single nonwoven fabric. As a result, the inventive separator permits a high strength material with low porosity and low pore size to levels unattained. The combination of polymeric nanofibers within a polymeric microfiber matrix and/or onto such a substrate through high shear processing provides such benefits, as well. The separator, a battery including such a separator, the method of manufacturing such a separator, and the method of utilizing such a separator within a battery device, are all encompassed within this invention.

Abstract: An insulating (nonconductive) microporous polymeric battery separator comprised of a single layer of enmeshed microfibers and nanofibers is provided. Such a separator accords the ability to attune the porosity and pore size to any desired level through a single nonwoven fabric. Through a proper selection of materials as well as production processes, the resultant battery separator exhibits isotropic strengths, low shrinkage, high wettability levels, and pore sizes related directly to layer thickness. The overall production method is highly efficient and yields a combination of polymeric nanofibers within a polymeric microfiber matrix and/or onto such a substrate through high shear processing that is cost effective as well. The separator, a battery including such a separator, the method of manufacturing such a separator, and the method of utilizing such a separator within a battery device, are all encompassed within this invention.

Abstract: An insulating (nonconductive) microporous polymeric battery separator comprised of a single layer of enmeshed microfibers and nanofibers is provided. Such a separator accords the ability to attune the porosity and pore size to any desired level through a single nonwoven fabric. Through a proper selection of materials as well as production processes, the resultant battery separator exhibits isotropic strengths, low shrinkage, high wettability levels, and pore sizes related directly to layer thickness. The overall production method is highly efficient and yields a combination of polymeric nanofibers within a polymeric microfiber matrix and/or onto such a substrate through high shear processing that is cost effective as well. The separator, a battery including such a separator, the method of manufacturing such a separator, and the method of utilizing such a separator within a battery device, are all encompassed within this invention.