A measurement apparatus includes an x-ray sensor including an x-ray source having a high voltage power supply for emitting an x-ray spectrum and an x-ray detector for providing a measured x-ray signal value responsive to the x-rays received after transmission through a coated substrate including a sheet material having a coating material thereon. A second sensor is a beta gauge or infrared sensor for providing a second sensor signal that includes data for determining a total weight per unit area of the coated substrate or of the sheet material A computing device receives the measured x-ray signal value and the second sensor signal configured to implement an x-ray based calculation that utilizes absorption coefficients for the coating material and sheet material, the measured x-ray signal value, the x-ray spectrum, and the weight measure as a calculation constraint, for computing at least the weight per unit area of the coating material.

A lithium secondary battery comprising a cathode, an anode, and a thermally stable polymer composite separator disposed between said cathode and said anode, wherein said composite separator comprises a thermally stable polymer, comprising a phosphorous-containing polymer, and from 30% to 99% by weight of particles of an inorganic material electrolyte and the particles are dispersed in or bonded by the thermally stable polymer, wherein the composite separator has a thickness from 50 nm to 100 μm and a lithium ion conductivity from 10.sup.−8 S/cm to 5×10.sup.−2 S/cm at room temperature.

A lithium secondary battery comprising a cathode, an anode, and a thermally stable polymer composite separator disposed between said cathode and said anode, wherein said composite separator comprises a thermally stable polymer, comprising a phosphorous-containing polymer, and from 30% to 99% by weight of particles of an inorganic material electrolyte and the particles are dispersed in or bonded by the thermally stable polymer, wherein the composite separator has a thickness from 50 nm to 100 μm and a lithium ion conductivity from 10.sup.−8 S/cm to 5×10.sup.−2 S/cm at room temperature.

A lithium secondary battery comprising a cathode, an anode, and a thermally stable polymer composite separator disposed between the cathode and the anode, wherein the polymer composite separator comprises (i) a thermally stable polymer; (ii) from 0.1% to 30% by weight of a lithium salt dispersed in the thermally stable polymer; and (iii) from 30% to 99% by weight of particles of an inorganic material wherein the inorganic material particles are dispersed in or bonded by the thermally stable polymer and the composite separator has a thickness from 50 nm to 100 μm and a lithium ion conductivity from 10.sup.−8 S/cm to 5×10.sup.−2 S/cm at room temperature. Also provided are the thermally stable and ion-conducting polymer composite separators and a process for producing such a separator.

A lithium secondary battery comprising a cathode, an anode, and a thermally stable polymer composite separator disposed between the cathode and the anode, wherein the polymer composite separator comprises (i) a thermally stable polymer; (ii) from 0.1% to 30% by weight of a lithium salt dispersed in the thermally stable polymer; and (iii) from 30% to 99% by weight of particles of an inorganic material wherein the inorganic material particles are dispersed in or bonded by the thermally stable polymer and the composite separator has a thickness from 50 nm to 100 μm and a lithium ion conductivity from 10.sup.−8 S/cm to 5×10.sup.−2 S/cm at room temperature. Also provided are the thermally stable and ion-conducting polymer composite separators and a process for producing such a separator.

Disclosed is a method for producing polymer-encapsulated Li.sub.2S.sub.x (where 1≤x≤2) nanoparticles. The method comprises the step of forming a mixture of a polymer and sulfur. The method further comprises vulcanizing the mixture at a vulcanization temperature attained at a heating rate, in a vulcanization atmosphere, and electrochemically reducing a vulcanized product at a reduction potential. Also disclosed is a method for producing a battery component, the component comprising a cathode and a separator.

A separator for a battery formed from a polymer gel electrolyte that is disposed within the pores of a polymer mesh. The polymer gel electrolyte is formed from a crosslinked ion-conducting polymer and an ionic liquid. The separator is formed from a gel loaded with an electrolyte, which prevents issue with electrolyte leakage. The polymer mesh provides stability to the polymer gel electrolyte, allowing for use of thin films of the polymer gel electrolyte and use of soft polymer gel electrolytes.

A separator for a battery formed from a polymer gel electrolyte that is disposed within the pores of a polymer mesh. The polymer gel electrolyte is formed from a crosslinked ion-conducting polymer and an ionic liquid. The separator is formed from a gel loaded with an electrolyte, which prevents issue with electrolyte leakage. The polymer mesh provides stability to the polymer gel electrolyte, allowing for use of thin films of the polymer gel electrolyte and use of soft polymer gel electrolytes.

An EB-PVD technique was used to fabricate ceramic/polymer/ceramic (LAGP/PE/LAGP) hybrid separator for rechargeable LIBs and Li batteries. The application of a ceramic electrolyte (LAGP) layer on traditional PE separator soaked in 1-M LiAsF.sub.6 liquid electrolyte combined the best attributes of traditional PE separator and solid inorganic electrolytes. The synergistic behavior of hybrid separator resulted in a high mechanical stability/flexibility, increased liquid uptake, high ion conduction, reduced cell voltage polarization, no lithium dendrite formation, and increased usable lithium content as compared to the state-of-the-art PE separator used in LIBs. The functional separator can be used to prolong life cycle and power capability of present LIBs. Thickness and density optimization of LAGP or similar electrolytes on polymer or other battery separators and their use in full Li battery (LIB, Li—S, Li—O.sub.2, Li—Ph, flow battery) cells are expected to further improve performance.

An EB-PVD technique was used to fabricate ceramic/polymer/ceramic (LAGP/PE/LAGP) hybrid separator for rechargeable LIBs and Li batteries. The application of a ceramic electrolyte (LAGP) layer on traditional PE separator soaked in 1-M LiAsF.sub.6 liquid electrolyte combined the best attributes of traditional PE separator and solid inorganic electrolytes. The synergistic behavior of hybrid separator resulted in a high mechanical stability/flexibility, increased liquid uptake, high ion conduction, reduced cell voltage polarization, no lithium dendrite formation, and increased usable lithium content as compared to the state-of-the-art PE separator used in LIBs. The functional separator can be used to prolong life cycle and power capability of present LIBs. Thickness and density optimization of LAGP or similar electrolytes on polymer or other battery separators and their use in full Li battery (LIB, Li—S, Li—O.sub.2, Li—Ph, flow battery) cells are expected to further improve performance.