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.

Energy storage devices, battery cells, and batteries may include a battery cell component that is formed by a method that includes forming a slurry that includes a ceramic material, a binder, and an ionic dispersant. The ceramic material may be greater than 50% of the slurry by weight. The method may also include applying the slurry to a polymeric material to form a two-layer separator. The slurry may be applied to a thickness of less than or about 10 μm.

A lithium-ion battery separator includes a substrate defining inter-particle pores and a zeolite coating on a surface of the substrate. The zeolite coating includes zeolite particles. The zeolite particles are hydrophobic and have an average diameter smaller than an average pore size of inter-particle pores of the substrate, such that some of the zeolite particles are positioned in some of the inter-particle pores. The separator is non-flammable In a lithium-ion battery, the substrate is a first electrode, and a second electrode is in direct contact with the zeolite coating. The lithium-ion battery includes a non-flammable salt-concentrated electrolyte, and the zeolite coating has a high wettability for the electrolyte. The lithium-ion battery is non-flammable.

A lithium-ion battery separator includes a substrate defining inter-particle pores and a zeolite coating on a surface of the substrate. The zeolite coating includes zeolite particles. The zeolite particles are hydrophobic and have an average diameter smaller than an average pore size of inter-particle pores of the substrate, such that some of the zeolite particles are positioned in some of the inter-particle pores. The separator is non-flammable In a lithium-ion battery, the substrate is a first electrode, and a second electrode is in direct contact with the zeolite coating. The lithium-ion battery includes a non-flammable salt-concentrated electrolyte, and the zeolite coating has a high wettability for the electrolyte. The lithium-ion battery is non-flammable.

Separators for zinc metal batteries, zinc metal batteries, and methods of fabricating a separator for use in a zinc metal battery are provided. The separator includes a hydrophilic membrane having a first side for facing a negative electrode when arranged in the zinc metal battery and a second side for facing a positive electrode when arranged in the zinc metal battery. The hydrophilic membrane includes a plurality of pores traversing the hydrophilic membrane from the first side to the second side enabling flow of zinc cations between the negative electrode and the positive electrode through the separator. Each of the pores may have a pore size ranging from about 0.1 to 1.3 μm.

Separators for zinc metal batteries, zinc metal batteries, and methods of fabricating a separator for use in a zinc metal battery are provided. The separator includes a hydrophilic membrane having a first side for facing a negative electrode when arranged in the zinc metal battery and a second side for facing a positive electrode when arranged in the zinc metal battery. The hydrophilic membrane includes a plurality of pores traversing the hydrophilic membrane from the first side to the second side enabling flow of zinc cations between the negative electrode and the positive electrode through the separator. Each of the pores may have a pore size ranging from about 0.1 to 1.3 μm.

Provided are separators for use in an electrochemical cell comprising (a) an inorganic oxide and (b) an organic polymer, wherein the inorganic oxide comprises organic substituents. Also provided are electrochemical cells comprising such separators.

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 calendering 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.

The present disclosure describes various types of batteries, including lithium-ion batteries having an anode assembly comprising: an anode comprising a first porous ceramic matrix having pores; and a ceramic separator layer affixed directly or indirectly to the anode; a cathode; an anode-side current collector contacting the anode; and anode active material comprising lithium located within the pores or cathode active material located within the cathode; wherein, the ceramic separator layer is located between the anode and the cathode, no electrically conductive coating on the pores contacts the separator layer, and in a fully charged state, lithium active material in the anode does not contact the separator layer. Also disclosed are methods of making and methods of using such batteries.

The present disclosure describes various types of batteries, including lithium-ion batteries having an anode assembly comprising: an anode comprising a first porous ceramic matrix having pores; and a ceramic separator layer affixed directly or indirectly to the anode; a cathode; an anode-side current collector contacting the anode; and anode active material comprising lithium located within the pores or cathode active material located within the cathode; wherein, the ceramic separator layer is located between the anode and the cathode, no electrically conductive coating on the pores contacts the separator layer, and in a fully charged state, lithium active material in the anode does not contact the separator layer. Also disclosed are methods of making and methods of using such batteries.