Abstract: A battery includes an anode, a cathode, and a porous separator having a surface and percolating pores providing a porosity of from 20% to 80%. A passively impact resistant composite electrolyte includes an electrolyte and electrically non-conducting particles that enable shear thickening. The particles can have a polydispersity index of no greater than 0.1, an average particle size in a range of from 50 nm to 1 um, and an absolute zeta potential of greater than ±40 mV. The shear thickening enabling particles can be from 10 wt. % to 40 wt. % of the total weight of the separator and shear thickening particles. Between 20-40 wt. % of the shear thickening enabling particles are located in the pores of the separator.

Abstract: A method of making a passively impact resistant battery includes the steps of providing a porous separator material having pores and a surface, and providing a suspension composition including shear thickening enabling particles and a particle suspension solvent for suspending the shear thickening enabling particles. The shear thickening particles have a polydispersity index of no greater than 0.1, an average particle size of in a range of 50 nm to 1 um, and an absolute zeta potential of greater than ±40 mV. The suspension composition is applied to the separator material, wherein a portion of the particles and suspension solvent penetrate the pores. The suspension solvent is evaporated from the separator material. An anode layer and a cathode layer are applied. An electrolyte composition is applied between the anode layer and the cathode layer. The electrolyte composition includes an electrolyte solvent and an electrolyte salt.

Abstract: A method of making a passively impact resistant battery includes the steps of providing a porous separator material having pores and a surface, and providing a suspension composition including shear thickening enabling particles and a particle suspension solvent for suspending the shear thickening enabling particles. The shear thickening particles have a polydispersity index of no greater than 0.1, an average particle size of in a range of 50 nm to 1 um, and an absolute zeta potential of greater than ±40 mV. The suspension composition is applied to the separator material, wherein a portion of the particles and suspension solvent penetrate the pores. The suspension solvent is evaporated from the separator material. An anode layer and a cathode layer are applied. An electrolyte composition is applied between the anode layer and the cathode layer. The electrolyte composition includes an electrolyte solvent and an electrolyte salt.

Abstract: A battery includes an anode, a cathode, and a porous separator having a surface and percolating pores providing a porosity of from 20% to 80%. A passively impact resistant composite electrolyte includes an electrolyte and electrically non-conducting particles that enable shear thickening. The particles can have a polydispersity index of no greater than 0.1, an average particle size in a range of from 50 nm to 1 um, and an absolute zeta potential of greater than ±40 mV. The shear thickening enabling particles can be from 10 wt. % to 40 wt. % of the total weight of the separator and shear thickening particles. Between 20-40 wt. % of the shear thickening enabling particles are located in the pores of the separator.

Abstract: A method for manufacturing an improved thin film composite solid electrolyte is provided. The method includes spray coating an aqueous suspension of ceramic particles onto a substrate to form a ceramic thin film. The film is sintered to form a porous ceramic structure having an interconnected necked morphology that defines cavities. The cavities are backfilled with an polymer electrolyte, for example a crosslinkable poly(ethylene oxide) (PEO)-based polymer electrolyte. The resulting thin film composite solid electrolyte is highly ionically conductive and mechanically robust with good manufacturability, particularly suitable for, but not limited to lithium metal batteries. The present method represents a departure from conventional mixing-then-casting methods and instead includes the fabrication of a solid electrolyte having a high ceramic volume fraction, high ionic conductivity, low thickness, and good chemical stability with metallic lithium.

Abstract: A method of making a passively impact resistant composite electrolyte and separator layer includes providing a suspension composition including electrically non-conducting particles that enable shear thickening. The particles can have a polydispersity index of no greater than 0.1, an average particle size in a range of from 50 nm to 1 um, and an absolute zeta potential of greater than ±40 mV. A particle suspension solvent is provided for suspending the particles. The suspension composition is applied to a porous separator material. A portion of the particles and suspension solvent penetrate the pores and the remainder of the particles in the suspension composition are distributed across the surface of the separator material. The suspension solvent is evaporated from the separator material to provide a shear thickening particle loaded separator. A separator assembly and a passivated battery are also disclosed.

Abstract: A method of making a passively impact resistant composite electrolyte and separator layer includes providing a suspension composition including electrically non-conducting particles that enable shear thickening. The particles can have a polydispersity index of no greater than 0.1, an average particle size in a range of from 50 nm to 1 um, and an absolute zeta potential of greater than ±40 mV. A particle suspension solvent is provided for suspending the particles. The suspension composition is applied to a porous separator material. A portion of the particles and suspension solvent penetrate the pores and the remainder of the particles in the suspension composition are distributed across the surface of the separator material. The suspension solvent is evaporated from the separator material to provide a shear thickening particle loaded separator. A separator assembly and a passivated battery are also disclosed.

Abstract: A method of making a passively impact resistant composite electrolyte and separator layer includes providing a suspension composition including electrically non-conducting particles that enable shear thickening. The particles can have a polydispersity index of no greater than 0.1, an average particle size in a range of from 50 nm to 1 um, and an absolute zeta potential of greater than ±40 mV. A particle suspension solvent is provided for suspending the particles. The suspension composition is applied to a porous separator material. A portion of the particles and suspension solvent penetrate the pores and the remainder of the particles in the suspension composition are distributed across the surface of the separator material. The suspension solvent is evaporated from the separator material to provide a shear thickening particle loaded separator. A separator assembly and a passivated battery are also disclosed.

Abstract: A method of making a passively impact resistant composite electrolyte and separator layer includes providing a suspension composition including electrically non-conducting particles that enable shear thickening. The particles can have a polydispersity index of no greater than 0.1, an average particle size in a range of from 50 nm to 1 um, and an absolute zeta potential of greater than ±40 mV. A particle suspension solvent is provided for suspending the particles. The suspension composition is applied to a porous separator material. A portion of the particles and suspension solvent penetrate the pores and the remainder of the particles in the suspension composition are distributed across the surface of the separator material. The suspension solvent is evaporated from the separator material to provide a shear thickening particle loaded separator. A separator assembly and a passivated battery are also disclosed.

Abstract: A passively impact resistant composite electrolyte composition includes an electrolyte solvent, up to 6M of an electrolyte salt, and shear thickening ceramic particles having an outer surface. The shear thickening ceramic particles have an absolute zeta potential of greater than ±40 mV. The shear thickening ceramic particles have a polydispersity index of no greater than 0.1, and an average particle size of in a range of 50 nm to 1 um. The ceramic particles have bonded to the outer surface steric stabilizing polymers. The steric stabilizing polymers have a chain length of from 0.5 nm to 100 nm. A passively impact resistant laminated battery and a method of making the electrolyte composition are also disclosed.

Abstract: A passively impact resistant composite electrolyte composition includes an aprotic electrolyte solvent, from 0.5 to 6M of an electrolyte salt, and shear thickening particles having a polydispersity index of no greater than 0.1, an average particle size in a range of 50 nm to 1 um, and an absolute zeta potential of greater than ±40 mV. The shear thickening particles have thereon an electrochemical double layer. The composition further includes a stabilizing surfactant. The stabilizing surfactant includes a first portion for adsorbing to the particles, and a second portion that is absorbed in the solvent. The length of the surfactant from the first portion to the second portion is greater than twice the thickness of the electrochemical double layer. Batteries and electrochemical devices incorporating the electrolyte composition are disclosed. Methods of making the electrolyte composition and of operating a battery are also disclosed.

Abstract: A passively impact resistant composite electrolyte composition includes an aprotic electrolyte solvent, from 0.5 to 6M of an electrolyte salt, and shear thickening particles having a polydispersity index of no greater than 0.1, an average particle size in a range of 50 nm to 1 um, and an absolute zeta potential of greater than ±40 mV. The shear thickening particles have thereon an electrochemical double layer. The composition further includes a stabilizing surfactant. The stabilizing surfactant includes a first portion for adsorbing to the particles, and a second portion that is absorbed in the solvent. The length of the surfactant from the first portion to the second portion is greater than twice the thickness of the electrochemical double layer. Batteries and electrochemical devices incorporating the electrolyte composition are disclosed. Methods of making the electrolyte composition and of operating a battery are also disclosed.

Abstract: A passively impact resistant composite electrolyte composition includes an electrolyte solvent, up to 6M of an electrolyte salt, and shear thickening ceramic particles having an outer surface. The shear thickening ceramic particles have an absolute zeta potential of greater than ±40 mV. The shear thickening ceramic particles have a polydispersity index of no greater than 0.1, and an average particle size of in a range of 50 nm to 1 um. The ceramic particles have bonded to the outer surface steric stabilizing polymers. The steric stabilizing polymers have a chain length of from 0.5 nm to 100 nm. A passively impact resistant laminated battery and a method of making the electrolyte composition are also disclosed.

Abstract: A method of drying casted slurries that includes calculating drying conditions from an experimental model for a cast slurry and forming a cast film. An infrared heating probe is positioned on one side of the casted slurry and a thermal probe is positioned on an opposing side of the casted slurry. The infrared heating probe may control the temperature of the casted slurry during drying. The casted slurry may be observed with an optical microscope, while applying the drying conditions from the experimental model. Observing the casted slurry includes detecting the incidence of micro-structural changes in the casted slurry during drying to determine if the drying conditions from the experimental model are optimal.