Novel or improved microporous single or multilayer battery separator membranes, separators, batteries including such membranes or separators, methods of making such membranes, separators, and/or batteries, and/or methods of using such membranes, separators and/or batteries are provided. In accordance with at least certain embodiments, a multilayer dry process polyethylene/polypropylene/polyethylene microporous separator which is manufactured using the inventive process which includes machine direction stretching followed by transverse direction stretching and a subsequent calendaring step as a means to reduce the thickness of the multilayer microporous membrane, to reduce the percent porosity of the multilayer microporous membrane in a controlled manner and/or to improve transverse direction tensile strength. In a very particular embodiment, the inventive process produces a thin multilayer microporous membrane that is easily coated with polymeric-ceramic coatings, has excellent mechanical strength properties due to its polypropylene layer or layers and a thermal shutdown function due to its polyethylene layer or layers. The ratio of the thickness of the polypropylene and polyethylene layers in the inventive multilayer microporous membrane can be tailored to balance mechanical strength and thermal shutdown properties.

In at least one embodiment, a separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. New or improved mats, separators, batteries, methods, and/or systems are also disclosed, shown, claimed, and/or provided. For example, in at least one possibly preferred embodiment, a composite separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. In at least one possibly particularly preferred embodiment, a PE membrane separator is provided with at least one fibrous mat for retaining the active material on an electrode of a lead-acid battery. In accordance with at least certain embodiments, aspects and/or objects, the present invention, application, or disclosure may provide solutions, new products, improved products, new methods, and/or improved methods, and/or may address issues, needs, and/or problems of PAM shedding, NAM shedding, electrode distortion, active material shedding, active material loss, and/or physical separation, electrode effectiveness, battery performance, battery life, and/or cycle life, and/or may provide new battery separators, new battery technology, and/or new battery methods and/or systems that address the challenges arising from current lead acid batteries or battery systems, especially new battery separators, new battery technology, and/or new battery methods and/or systems adapted to prevent or impede the shedding of active material from the electrodes, preferably or particularly in enhanced flooded lead acid batteries, PSoC batteries, ISS batteries, ESS batteries, and/or the like.

In at least one embodiment, a separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. New or improved mats, separators, batteries, methods, and/or systems are also disclosed, shown, claimed, and/or provided. For example, in at least one possibly preferred embodiment, a composite separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. In at least one possibly particularly preferred embodiment, a PE membrane separator is provided with at least one fibrous mat for retaining the active material on an electrode of a lead-acid battery. In accordance with at least certain embodiments, aspects and/or objects, the present invention, application, or disclosure may provide solutions, new products, improved products, new methods, and/or improved methods, and/or may address issues, needs, and/or problems of PAM shedding, NAM shedding, electrode distortion, active material shedding, active material loss, and/or physical separation, electrode effectiveness, battery performance, battery life, and/or cycle life, and/or may provide new battery separators, new battery technology, and/or new battery methods and/or systems that address the challenges arising from current lead acid batteries or battery systems, especially new battery separators, new battery technology, and/or new battery methods and/or systems adapted to prevent or impede the shedding of active material from the electrodes, preferably or particularly in enhanced flooded lead acid batteries, PSoC batteries, ISS batteries, ESS batteries, and/or the like.

The present invention pertains to an anode-less lithium ion battery comprising a) a cathode comprising a cathode current collector and a cathode electro-active material on the cathode current collector; b) an anode current collector; c) a liquid electrolyte composition between the a) cathode and the b) anode current collector; and d) a separator, wherein the c) liquid electrolyte composition comprises i) at least 70% by volume (vol %) of a solvent mixture with respect to the total volume of the electrolyte composition, comprising at least one fluorinated ether compound and at least one non-fluorinated ether compound, and ii) at least one lithium salt.

There is provided a method for producing a separator for an electricity storage device that includes a step of contacting a porous body formed from a silane-modified polyolefin-containing molded sheet with a base solution or acid solution, and a separator for an electricity storage device comprising a microporous film with a melted film rupture temperature of 180° C. to 220° C. as measured by thermomechanical analysis (TMA).

Embodiments of this application provide a battery separator, including a polyolefin-based porous separator, where the polyolefin-based porous separator includes polyethylene resin, an elongation rate of the polyolefin-based porous separator in an MD direction is greater than 120%, an elongation rate in a TD direction is greater than 120%, and for the polyolefin-based porous separator, crystallinity at a first-time temperature rise of polyethylene that is measured by using a differential scanning calorimeter is less than 65%, crystallinity at a second-time temperature rise is less than 55%, and a difference between the crystallinity at the first-time temperature rise and the crystallinity at the second-time temperature rise is less than 12%. The battery separator features a high elongation rate and a low temperature of closing a pore.

A separator for a secondary battery, including a porous polymer substrate; a porous coating layer on at least one surface of the porous polymer substrate. The porous coating layer includes a plurality of inorganic particles and a first binder polymer that interconnects and fixes the inorganic particles; and an adhesive layer on a surface of the porous coating layer opposite to the porous polymer substrate. The adhesive layer includes a second binder polymer, and the adhesive layer includes a first layer in contact with the surface of the porous coating layer opposite to the porous polymer substrate, and a second layer integrated with the first layer and the second layer faces an electrode. The second layer has an average pore size larger than the average pore size of the first layer. The separator for a secondary battery can improve the problem related with resistance, while ensuring adhesion to an electrode.

A separator for a secondary battery, including a porous polymer substrate; a porous coating layer on at least one surface of the porous polymer substrate. The porous coating layer includes a plurality of inorganic particles and a first binder polymer that interconnects and fixes the inorganic particles; and an adhesive layer on a surface of the porous coating layer opposite to the porous polymer substrate. The adhesive layer includes a second binder polymer, and the adhesive layer includes a first layer in contact with the surface of the porous coating layer opposite to the porous polymer substrate, and a second layer integrated with the first layer and the second layer faces an electrode. The second layer has an average pore size larger than the average pore size of the first layer. The separator for a secondary battery can improve the problem related with resistance, while ensuring adhesion to an electrode.

A secondary battery that generates or includes metal-ion contaminants selected from copper ions, manganese ions, nickel ions, cobalt ions, iron ions, aluminum ions, chrome ions, molybdenum ions, tin ions or combinations thereof, the battery comprising: an anode; a cathode; a coated or uncoated battery separator between the anode and the cathode, wherein the coated or uncoated battery separator comprises a trap layer; and an electrolyte. The battery improve yield rate of initial charge and aging process and exhibits prolonged useful life due to the separator, which reduces or eliminates metal-ion contamination in the battery.

A secondary battery that generates or includes metal-ion contaminants selected from copper ions, manganese ions, nickel ions, cobalt ions, iron ions, aluminum ions, chrome ions, molybdenum ions, tin ions or combinations thereof, the battery comprising: an anode; a cathode; a coated or uncoated battery separator between the anode and the cathode, wherein the coated or uncoated battery separator comprises a trap layer; and an electrolyte. The battery improve yield rate of initial charge and aging process and exhibits prolonged useful life due to the separator, which reduces or eliminates metal-ion contamination in the battery.