A flame-resistant polymer composite separator for use in a lithium battery, wherein the polymer composite separator comprises (a) a binder or matrix polymer; (b) 0.1% to 50% by weight of a lithium salt dispersed in the polymer; and (c) from 30% to 99% by weight of particles or fibers of an inorganic material or polymer fibers that are dispersed in or bonded by the polymer, wherein the polymer is a polymerization or crosslinking product of a reactive additive comprising (i) a first liquid solvent that is polymerizable, (ii) an initiator or crosslinking agent, and (iii) the lithium salt and wherein the polymer 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 ceramic-coated battery separator having a microporous polyolefin membrane and a ceramic coating on at least one surface of the microporous polyolefin membrane, wherein the ceramic-coated separator exhibits a strain shrinkage of 0% at temperatures greater than or equal to 120 degrees Celsius is provided.

The present invention relates to a method for manufacturing a single-layer or multi-layer porous film, said method comprising the following steps: a) providing a flowable first base mixture for a first film layer of the film, the first base mixture comprising a solvent, a filler that is insoluble in the solvent, and a polymeric binder that is dissolved in the solvent; b) forming a film precursor film, the film precursor film comprising at least one sub-layer composed of the first base mixture; c) bringing the film precursor film into contact with a precipitant, the solvent of the first base mixture being soluble in the precipitant, the binder being insoluble in the precipitant, and the binder being precipitated to form the porous film. The invention also relates to a film manufactured using said method, an electrode material manufactured from said film, and an energy storage medium comprising said electrode material.

The present invention relates to a method for manufacturing a single-layer or multi-layer porous film, said method comprising the following steps: a) providing a flowable first base mixture for a first film layer of the film, the first base mixture comprising a solvent, a filler that is insoluble in the solvent, and a polymeric binder that is dissolved in the solvent; b) forming a film precursor film, the film precursor film comprising at least one sub-layer composed of the first base mixture; c) bringing the film precursor film into contact with a precipitant, the solvent of the first base mixture being soluble in the precipitant, the binder being insoluble in the precipitant, and the binder being precipitated to form the porous film. The invention also relates to a film manufactured using said method, an electrode material manufactured from said film, and an energy storage medium comprising said electrode material.

In one embodiment of the present invention, it is provided a method of manufacturing a separator comprising:

preparing expansion graphite; pulverizing the expansion graphite; mixing the expansion graphite and polymer; and forming a separator by molding the mixture.

In one embodiment of the present invention, it is provided a method of manufacturing a separator comprising:

preparing expansion graphite; pulverizing the expansion graphite; mixing the expansion graphite and polymer; and forming a separator by molding the mixture.

A method of co-extruding battery components includes forming a first thin film battery component via hot melt extrusion, and forming a second thin film battery component via hot melt extrusion. A surface treatment is applied to a surface region of at least one of the first and second components so that, relative to a remainder of the at least one component, the surface region has at least one of a decreased inter-particle distance, a decreased amount of polymer binder material, and an increased amount of exposed ionically conductive material. The first and second components are fed through a co-extrusion die to form a co-extruded multilayer thin film.

A method of co-extruding battery components includes forming a first thin film battery component via hot melt extrusion, and forming a second thin film battery component via hot melt extrusion. A surface treatment is applied to a surface region of at least one of the first and second components so that, relative to a remainder of the at least one component, the surface region has at least one of a decreased inter-particle distance, a decreased amount of polymer binder material, and an increased amount of exposed ionically conductive material. The first and second components are fed through a co-extrusion die to form a co-extruded multilayer thin film.

A separator plate arrangement for an electrochemical system, comprising a first metal sheet and a second metal sheet. The first metal sheet has a first circumferential sealing structure for sealing off an electrochemically active region, a first cutout arranged outside of the first circumferential sealing structure, and a first embossed structure arranged outside of the first circumferential sealing structure. The second metal sheet has a second circumferential sealing structure for sealing off an electrochemically active region, a second cutout arranged outside of the second circumferential sealing structure, and a second embossed structure arranged outside of the second circumferential sealing structure.

A separator plate arrangement for an electrochemical system, comprising a first metal sheet and a second metal sheet. The first metal sheet has a first circumferential sealing structure for sealing off an electrochemically active region, a first cutout arranged outside of the first circumferential sealing structure, and a first embossed structure arranged outside of the first circumferential sealing structure. The second metal sheet has a second circumferential sealing structure for sealing off an electrochemically active region, a second cutout arranged outside of the second circumferential sealing structure, and a second embossed structure arranged outside of the second circumferential sealing structure.