Disclosed herein are a multilayer separator for a lithium secondary battery capable of preventing an internal short-circuit due to growth of lithium dendrite, and a method of manufacturing the same.

Disclosed herein are a multilayer separator for a lithium secondary battery capable of preventing an internal short-circuit due to growth of lithium dendrite, and a method of manufacturing the same.

The invention discloses a method of manufacturing an electrochemical cell having a polymer separator membrane for separation of electrodes in the electrochemical cell, including providing a cathode and providing a polymer separator membrane. At least one cycle of irradiating the polymer separator membrane is performed by an energy beam under a radiation dose ranging between 50 and 200 kGy to effect a cross-linking in the polymer separator membrane. The polymer separator membrane is maintained at a temperature between 30° C. and 70° C. An anode is then provided. Subsequently, the polymer separator membrane is compressed between the cathode and the anode. An electrolyte is provided to form the electrochemical cell.

The invention discloses a method of manufacturing an electrochemical cell having a polymer separator membrane for separation of electrodes in the electrochemical cell, including providing a cathode and providing a polymer separator membrane. At least one cycle of irradiating the polymer separator membrane is performed by an energy beam under a radiation dose ranging between 50 and 200 kGy to effect a cross-linking in the polymer separator membrane. The polymer separator membrane is maintained at a temperature between 30° C. and 70° C. An anode is then provided. Subsequently, the polymer separator membrane is compressed between the cathode and the anode. An electrolyte is provided to form the electrochemical cell.

A method for producing a microporous material comprising the steps of: providing an ultrahigh molecular weight polyethylene (UHMWPE); providing a filler; providing a processing plasticizer; adding the filler to the UHMWPE in a mixture being in the range of from about 1:9 to about 15:1 filler to UHMWPE by weight; adding the processing plasticizer to the mixture; extruding the mixture to form a sheet from the mixture; calendering the sheet; extracting the processing plasticizer from the sheet to produce a matrix comprising UHMWPE and the filler distributed throughout the matrix; stretching the microporous material in at least one direction to a stretch ratio of at least about 1.5 to produce a stretched microporous matrix; and subsequently calendering the stretched microporous matrix to produce a microporous material which exhibits improved physical and dimensional stability properties over the stretched microporous matrix.

A method for producing a microporous material comprising the steps of: providing an ultrahigh molecular weight polyethylene (UHMWPE); providing a filler; providing a processing plasticizer; adding the filler to the UHMWPE in a mixture being in the range of from about 1:9 to about 15:1 filler to UHMWPE by weight; adding the processing plasticizer to the mixture; extruding the mixture to form a sheet from the mixture; calendering the sheet; extracting the processing plasticizer from the sheet to produce a matrix comprising UHMWPE and the filler distributed throughout the matrix; stretching the microporous material in at least one direction to a stretch ratio of at least about 1.5 to produce a stretched microporous matrix; and subsequently calendering the stretched microporous matrix to produce a microporous material which exhibits improved physical and dimensional stability properties over the stretched microporous matrix.

Disclosed are a composite solid electrolyte separation membrane using inorganic fiber and a secondary battery using the same, the composite solid electrolyte separation membrane including inorganic fiber, a sodium oxide-based ceramic material impregnated into the inorganic fiber, and an electrolyte impregnated into the inorganic fiber into which the sodium oxide-based ceramic material is impregnated.

Disclosed are a composite solid electrolyte separation membrane using inorganic fiber and a secondary battery using the same, the composite solid electrolyte separation membrane including inorganic fiber, a sodium oxide-based ceramic material impregnated into the inorganic fiber, and an electrolyte impregnated into the inorganic fiber into which the sodium oxide-based ceramic material is impregnated.

A multilayer porous membrane with two exterior layers and at least one interior layer. The average pore size of the interior layer is greater than that of either of the two exterior layers. The multilayer porous membrane may be used, for example, as or as part of a battery separator. Compared to prior multilayer porous membranes for battery separators, the multilayer porous membrane herein may exhibit at least one of improved thermal properties, improved anti-metal contamination properties, improved ease of manufacture, and combinations thereof.

A multilayer porous membrane with two exterior layers and at least one interior layer. The average pore size of the interior layer is greater than that of either of the two exterior layers. The multilayer porous membrane may be used, for example, as or as part of a battery separator. Compared to prior multilayer porous membranes for battery separators, the multilayer porous membrane herein may exhibit at least one of improved thermal properties, improved anti-metal contamination properties, improved ease of manufacture, and combinations thereof.