A separator with a heat-resistant insulation layer for an electric device includes a resin porous substrate and a heat-resistant insulation layer containing heat-resistant particles and a binder, the heat-resistant insulation layer being formed on at least one surface of the resin porous substrate. The heat-resistant particles contain alumina and a parameter X is 0.018 to 0.336. Parameter X is represented by X=C.sub.a×R.sub.zjis/D, wherein C.sub.α is a ratio of the alumina, which occupies the heat-resistant particles, R.sub.zjis is surface roughness of a surface of the heat-resistant insulation layer, the surface being opposite the resin porous substrate, and D is a thickness of the heat-resistant insulation layer.

The present invention provides a lithium-air battery comprising: an air electrode using oxygen as a positive electrode active material; a negative electrode which is disposed apart from the positive electrode; and a separator which is immersed in an electrolyte disposed between the positive electrode and the negative electrode, wherein the air electrode comprises a gas diffusion layer coated with a conductive material, and the separator has a part coated with the conductive material.

This invention provides a novel battery structure that, in some variations, utilizes a mixed lithium-ion and electron conductor as part of the separator. This layer is non-porous, conducting only lithium ions during operation, and may be structurally free-standing. Alternatively, the layer can be used as a battery electrode in a lithium-ion battery, wherein on the side not exposed to battery electrolyte, a chemical compound is used to regenerate the discharged electrode. This battery structure overcomes critical shortcomings of current lithium-sulfur, lithium-air, and lithium-ion batteries.

Embodiments of the invention provide batteries, electrodes, and methods of making the same. According to one embodiment, a battery may include a positive plate having a grid pasted with a lead oxide material, a negative plate having a grid pasted with a lead based material, a separator separating the positive plate and the negative plate, and an electrolyte. A nonwoven glass mat may be in contact with a surface of either or both the positive plate or the negative plate to reinforce the plate. The nonwoven glass mat may include a plurality of first coarse fibers having fiber diameters between about 6 μm and 11 μm and a plurality of second coarse fibers having fiber diameters between about 10 μm and 20 μm.

A battery cell interface material provides multiple types of protection between adjacent cells of an electric vehicle battery pack is provided. The interface material is an integral wall assembly having the following: a middle wall constructed of one of interlaced multifilament flame-resistant yarn or a non-woven material, the middle wall having opposite sides. A pair of intermediate layers, with each intermediate layer being bonded to a separate one of the opposite sides of the middle wall. A pair of outer layers, with each outer layer being bonded to a separate one of the pair of intermediate layers, such that each intermediate layer is sandwiched between one of the pair of outer layers and the textile middle wall, with each outer layer facing a cell wall of the electric vehicle battery being configured to be bonded directly to the cell wall.

A battery cell interface material provides multiple types of protection between adjacent cells of an electric vehicle battery pack is provided. The interface material is an integral wall assembly having the following: a middle wall constructed of one of interlaced multifilament flame-resistant yarn or a non-woven material, the middle wall having opposite sides. A pair of intermediate layers, with each intermediate layer being bonded to a separate one of the opposite sides of the middle wall. A pair of outer layers, with each outer layer being bonded to a separate one of the pair of intermediate layers, such that each intermediate layer is sandwiched between one of the pair of outer layers and the textile middle wall, with each outer layer facing a cell wall of the electric vehicle battery being configured to be bonded directly to the cell wall.

Provided herein is a separator used for an electrochemical device such as a lithium-ion battery. The separator disclosed herein comprises a porous base material, and a protective porous layer coated on one or both surfaces of the porous base material disclosed herein, wherein the protective porous layer comprises an organic binder and an inorganic filler, and wherein a difference in tensile strength of the separator along the TD direction and MD direction is about 15% or less. Also provided herein is a lithium-ion battery including the separator disclosed herein. The separator disclosed herein is excellent in terms of safety, ion permeability, and cycle characteristics.

Provided herein is a separator used for an electrochemical device such as a lithium-ion battery. The separator disclosed herein comprises a porous base material, and a protective porous layer coated on one or both surfaces of the porous base material disclosed herein, wherein the protective porous layer comprises an organic binder and an inorganic filler, and wherein the inorganic filler comprises a whisker-type material selected from the group consisting of Al.sub.2O.sub.3, SiO.sub.2, TiO.sub.2, ZrO.sub.2, BaO.sub.x, ZnO, CaCO.sub.3, TiN, AlN, MTiO.sub.3, K.sub.2O.nTiO.sub.2, Na.sub.2O.mTiO.sub.2, and combinations thereof, wherein x is 1 or 2; M is Ba, Sr or Ca; n is 1, 2, 4, 6 or 8; and m is 3 or 6. Also provided herein is a lithium-ion battery including the separator disclosed herein. The separator disclosed herein is excellent in terms of safety, ion permeability, and cycle characteristics.

Provided herein is a separator used for an electrochemical device such as a lithium-ion battery. The separator disclosed herein comprises a porous base material, a first protective porous layer coated on one side of the porous base material, and a second protective porous layer coated on the other side of the porous base material, wherein the first protective porous layer comprises an organic binder and a first inorganic filler, and wherein the second protective porous layer comprises an organic binder and a second inorganic filler different from the first inorganic filler. Also provided herein is a lithium-ion battery including the separator disclosed herein. The separator disclosed herein is excellent in terms of safety, ion permeability, and cycle characteristics.

In an embodiment of the present disclosure, provided is a separator for a non-aqueous electrolyte battery, the separator being composed of a composite membrane comprising: a porous substrate; and an adhesive porous layer provided on one side or both sides of the porous substrate and containing an adhesive resin, wherein the adhesive porous layer further contains an acrylic resin in a state in which the acrylic resin is mixed with the adhesive resin, a peel strength between the porous substrate and the adhesive porous layer is 0.20 N/10 mm or more, and a Gurley value is 200 sec/100 cc or less.