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 separator for spatially separating and electrically isolating electrodes in a battery cell. The separator has a receptacle for at least one galvanic cell which includes an anode and a cathode; a structure composed of conductive material for electrically connecting the anode and cathode to one another and for making contact with the at least one galvanic cell from outside; and a duct system for forming a cooling fluid flow in the separator. At least the receptacle and the duct system are integrally formed in the separator.

A separator for spatially separating and electrically isolating electrodes in a battery cell. The separator has a receptacle for at least one galvanic cell which includes an anode and a cathode; a structure composed of conductive material for electrically connecting the anode and cathode to one another and for making contact with the at least one galvanic cell from outside; and a duct system for forming a cooling fluid flow in the separator. At least the receptacle and the duct system are integrally formed in the separator.

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.

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 separator for a lithium secondary battery comprising a porous polymer substrate and a porous coating layer on at least one surface of the porous polymer substrate. The separator has an ionic conductivity of 4.75×10.sup.−5 S/cm or more, and the porous coating layer comprises an interstitial volume and a macro pore having a larger diameter than the interstitial volume. A method for manufacturing the separator is also disclosed. Accordingly, the separator has significantly improved ionic conductivity over commercial separators.

A separator for a lithium secondary battery comprising a porous polymer substrate and a porous coating layer on at least one surface of the porous polymer substrate. The separator has an ionic conductivity of 4.75×10.sup.−5 S/cm or more, and the porous coating layer comprises an interstitial volume and a macro pore having a larger diameter than the interstitial volume. A method for manufacturing the separator is also disclosed. Accordingly, the separator has significantly improved ionic conductivity over commercial separators.

In an aspect, a solid-state Li-ion battery (SSLB) cell, may comprise an anode electrode comprising an anode electrode surface and an anode active material, a cathode electrode comprising a cathode electrode surface and an cathode active material, and an inorganic, melt-infiltrated, solid state electrolyte (SSE) ionically coupling the anode electrode and the cathode electrode, wherein at least a portion of at least one of the electrode surfaces comprises an interphase layer separating the respective electrode active material from direct contact with the SSE, and wherein the interphase layer comprises two or more metals from the list of: Zr, Al, K, Cs, Fr, Be, Mg, Ca, Sr, Ba, Sc, Y, La or non-La lanthanoids, Ta, Zr, Hf, and Nb.

Embodiments described herein relate to electrochemical cells with multiple separators, and methods of producing the same. A method of producing an electrochemical cell can include disposing an anode material onto an anode current collector, disposing a first separator on the anode material, disposing a cathode material onto a cathode current collector, disposing a second separator onto the cathode material, and disposing the first separator on the second separator to form the electrochemical cell. The anode material and/or the cathode material can be a semi-solid electrode material including an active material, a conductive material, and a volume of liquid electrolyte. In some embodiments, less than about 10% by volume of the liquid electrolyte evaporates during the forming of the electrochemical cell. In some embodiments, the method can further include wetting the first separator and/or the second separator with an electrolyte solution prior to coupling the first separator to the second separator.

High performance flexible lithium-sulfur flexible energy storage devices include a flexible lithium metal anode for an energy storage device comprising an electrically conducting fabric functionalised with a 3D hierarchical MnO.sub.2 nanosheet lithiophilic material; a flexible graphene/sulfur cathode protected by a FBN/G interlayer; and a flexible separator for an energy storage device, wherein the separator comprises one or more microporous films of Li ion selective permeable polyolefin material wherein at least a portion of the pores of the film are associated with nanoporous polysulfone polymer positioned between the anode and the cathode.