A coated hybrid electrode for a composite solid-state battery cell is disclosed. Systems and methods are further provided for forming an electrolyte coating including a solid ionically conductive polymer material in the coated hybrid electrode. In one example, the coated hybrid electrode can include an anode material coating, the solid polymer electrolyte coating, and a cathode material coating, such that the solid polymer electrolyte coating can function as a separator coating between the anode material coating and the cathode material coating, thus eliminating a need for a conventional battery separator. In some examples, a slurry-based coating process can be utilized for forming the solid polymer electrolyte coating. As such, the solid polymer electrolyte coating can be mechanically robust with uniform thickness. Further, a battery cell can be formed by utilizing a sub-assembly stacking technique to provide battery cell stiffness and increase precision and accuracy of coating.

A coated hybrid electrode for a composite solid-state battery cell is disclosed. Systems and methods are further provided for forming an electrolyte coating including a solid ionically conductive polymer material in the coated hybrid electrode. In one example, the coated hybrid electrode can include an anode material coating, the solid polymer electrolyte coating, and a cathode material coating, such that the solid polymer electrolyte coating can function as a separator coating between the anode material coating and the cathode material coating, thus eliminating a need for a conventional battery separator. In some examples, a slurry-based coating process can be utilized for forming the solid polymer electrolyte coating. As such, the solid polymer electrolyte coating can be mechanically robust with uniform thickness. Further, a battery cell can be formed by utilizing a sub-assembly stacking technique to provide battery cell stiffness and increase precision and accuracy of coating.

An adhesive-coated separator for a lithium-ion battery, a preparation method thereof, and use thereof are disclosed. The adhesive-coated separator for a lithium-ion battery of the present disclosure includes a base membrane and an adhesive coating formed on a surface of the base membrane, the thickness deviation percentage of the adhesive coating is less than or equal to 10%, the thickness deviation percentage=(D.sub.max−D.sub.min)/D.sub.ave×100%, D.sub.max is a maximum value of the thickness of the adhesive coating, D.sub.min is a minimum value of the thickness of the adhesive coating, and D.sub.ave is an average value of the thickness of the adhesive coating.

An adhesive-coated separator for a lithium-ion battery, a preparation method thereof, and use thereof are disclosed. The adhesive-coated separator for a lithium-ion battery of the present disclosure includes a base membrane and an adhesive coating formed on a surface of the base membrane, the thickness deviation percentage of the adhesive coating is less than or equal to 10%, the thickness deviation percentage=(D.sub.max−D.sub.min)/D.sub.ave×100%, D.sub.max is a maximum value of the thickness of the adhesive coating, D.sub.min is a minimum value of the thickness of the adhesive coating, and D.sub.ave is an average value of the thickness of the adhesive coating.

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 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.

A nonaqueous electrolyte secondary battery separator film transfer device is provided which realizes a foreign object removing technique that is less likely to cause defects in a separator. The device includes a magnet bar which is arranged in a transfer path and generates a magnetic field for removing, from a separator film being transferred, a magnetic substance adhering to a first surface of the separator film; and an air cylinder which allows a distance to the magnet bar from the first surface of the separator film to be variable.

A separator is provided which includes: a separator base including a porous polymer substrate having a plurality of pores, and a porous coating layer positioned on at least one surface of the porous polymer substrate and containing a plurality of inorganic particles and a binder polymer positioned on the whole or a part of the surface of the inorganic particles to connect the inorganic particles with one another and fix them; and a porous adhesive layer positioned on at least one surface of the separator base and including polyvinylidene fluoride-co-hexafluoropropylene containing vinylidene fluoride-derived repeating units and hexafluoropropylene-derived repeating units, wherein the ratio of the number of the hexafluoropropylene (HFP)-derived repeating units (HFP substitution ratio) based on the total number of the vinylidene fluoride-derived repeating units and the hexafluoropropylene-derived repeating units is 4.5% to 9%. An electrochemical device including the separator is also provided.

A separator is provided which includes: a separator base including a porous polymer substrate having a plurality of pores, and a porous coating layer positioned on at least one surface of the porous polymer substrate and containing a plurality of inorganic particles and a binder polymer positioned on the whole or a part of the surface of the inorganic particles to connect the inorganic particles with one another and fix them; and a porous adhesive layer positioned on at least one surface of the separator base and including polyvinylidene fluoride-co-hexafluoropropylene containing vinylidene fluoride-derived repeating units and hexafluoropropylene-derived repeating units, wherein the ratio of the number of the hexafluoropropylene (HFP)-derived repeating units (HFP substitution ratio) based on the total number of the vinylidene fluoride-derived repeating units and the hexafluoropropylene-derived repeating units is 4.5% to 9%. An electrochemical device including the separator is also provided.

Provided are a separator for a secondary battery and an electrochemical device using the same. More particularly, a composite separator which has a lower Gurley permeability after curing than that before curing when forming a heat-resistant coating layer having low resistance, does not have a Gurley permeability which is greatly increased as compared with the Gurley permeability of a porous substrate itself before forming a coating layer to have an overall low Gurley permeability, and has a high surface hardness to have penetration stability, is provided.

Improved battery separators, base films or membranes, batteries, cells, devices, systems, vehicles, and/or methods of making and/or using such separators, films or membranes, batteries, cells, devices, systems, vehicles, and/or methods of enhancing battery or cell charge rates, charge capacity, and/or discharge rates, and/or methods of improving batteries, systems including such batteries, vehicles including such batteries and/or systems, and/or the like; biaxially oriented porous membranes, composites including biaxially oriented porous membranes, biaxially oriented microporous membranes, biaxially oriented macroporous membranes, battery separators with improved charge capacities and the related methods and methods of manufacture, methods of use, and the like; flat sheet membranes, liquid retention media; dry process separators; biaxially stretched separators; dry process biaxially stretched separators having a thickness range between about 5 μm and 50 μm, preferably between about 10 μm and 25 μm, having improved strength, high porosity, and unexpectedly and/or surprisingly high charge capacity, such as, for example, high 10 C rate charge capacity; separators or membranes with high charge capacity and high porosity, excellent charge rate and/or charge capacity performance in a rechargeable and/or secondary lithium battery, such as a lithium ion battery, for high power and/or high energy applications, cells, devices, systems, and/or vehicles, and/or the like; single or multiple ply or layer separators, monolayer separators, trilayer separators, composite separators, laminated separators, co-extruded separators, coated separators, 1 C or higher separators, at least 1 C separators, batteries, cells, systems, devices, vehicles, and/or the like; improved microporous battery separators for secondary lithium batteries, improved microporous battery separators with enhanced or high charge (C) rates, discharge (C) rates, and/or enhanced or high charge capacities in or for secondary lithium batteries, and/or related methods of manufacture, use, and/or the like, and/or combinations thereof are disclosed or provided.