CELGARD, LLC

The problems or issues faced by typical larger SSE batteries are solved by providing an interface or interfacial layer at least between the anode, which comprises Li or Na, and the solid state electrolyte (SSE). In some other embodiments, an interfacial layer may be provided between the anode, which comprises Li or Na, and the SSE, and an interface or interfacial layer may also be provided between the cathode and the SSE. In at least selected embodiments, aspects or objects, the interfacial layer may act as a shock absorber between a SSE (e.g., a sulfide glass SSE) and an anode material that is soft compared to the SSE (e.g., Li metal). In other embodiments, the interfacial layer may act as a shock absorber between the SSE and a cathode material that is softer than the SSE. In at least certain embodiments, the interfacial layer may improve ionic conductance between the anode and the SSE and/or the SSE and the cathode. In at least certain selected embodiments, the interfacial layer may prevent or deter lithium deposition and dendrite growth at the interface between the anode and the SSE. Interface defects at the interface between the anode and the SSE may allow lithium deposition and dendrite growth. The dendrites may continue to grow through cracks in the SSE causing a short, which is a safety issue. The inventive interfacial layer between the anode and the SSE may prevent or deter this. In at least some embodiments, the interfacial layer may be a porous polymer layer filled with liquid electrolyte and may improve ionic conductance between the anode and the SSE and/or the SSE and the cathode. In certain embodiments, the anode interface or interfacial layer may be a porous polymer layer filled with liquid electrolyte. In some embodiments, the cathode interface or interfacial layer may be a porous polymer layer filled with liquid, gel or polymer electrolyte.

The problems or issues faced by typical larger SSE batteries are solved by providing an interface or interfacial layer at least between the anode, which comprises Li or Na, and the solid state electrolyte (SSE). In some other embodiments, an interfacial layer may be provided between the anode, which comprises Li or Na, and the SSE, and an interface or interfacial layer may also be provided between the cathode and the SSE. In at least selected embodiments, aspects or objects, the interfacial layer may act as a shock absorber between a SSE (e.g., a sulfide glass SSE) and an anode material that is soft compared to the SSE (e.g., Li metal). In other embodiments, the interfacial layer may act as a shock absorber between the SSE and a cathode material that is softer than the SSE. In at least certain embodiments, the interfacial layer may improve ionic conductance between the anode and the SSE and/or the SSE and the cathode. In at least certain selected embodiments, the interfacial layer may prevent or deter lithium deposition and dendrite growth at the interface between the anode and the SSE. Interface defects at the interface between the anode and the SSE may allow lithium deposition and dendrite growth. The dendrites may continue to grow through cracks in the SSE causing a short, which is a safety issue. The inventive interfacial layer between the anode and the SSE may prevent or deter this. In at least some embodiments, the interfacial layer may be a porous polymer layer filled with liquid electrolyte and may improve ionic conductance between the anode and the SSE and/or the SSE and the cathode. In certain embodiments, the anode interface or interfacial layer may be a porous polymer layer filled with liquid electrolyte. In some embodiments, the cathode interface or interfacial layer may be a porous polymer layer filled with liquid, gel or polymer electrolyte.

In one aspect, a method of measuring the internal short resistance of a battery separator comprising one or more layers of a polyolefin is provided. A method comprises applying a force via a force component comprising a ball to a test stack, the test stack comprising an anode, a separator, and a cathode, deforming the test stack until an electrical short occurs, and determining an ISR value for the separator, the value corresponding to an overall ISR, or at least in one of the MD, TD, or Z-direction.

2 . A composite for forming an improved semi-solid state electrolyte. The composite has a layer formed including lithium metaphosphate (LiPO 3 ). The layer may include a mixture of LiPO 3 and PEO. The composite may be wet with liquid electrolyte to form the semi-solid state electrolyte. When used in a semi-solid state battery, the semi-solid state electrolyte provides beneficial results, including improved cycle life and less lithium dendrite growth. Another composite for forming an improved semi-solid state electrolyte has a layer formed including LiTaO 3 and LiNbO 3 . Yet another composite has a single layer formed to include a mixture of a polyethylene oxide and a lithium-containing salt, including a lithium salt including niobium, tantalum, or mixtures thereof. Such composites may be wet with liquid electrolyte to form the semi-solid state electrolyte. When used in a semi-solid state battery, the semi-solid state electrolyte provides beneficial results, including improved cycle life and less lithium dendrite growth.

A coated battery separator is described herein. The coated battery separator includes a porous membrane with a coating on at least one side thereof, wherein the coated separator exhibits at least one of improved thickness uniformity of the coating and improved adhesion of the coating to the porous membrane. In some embodiments, the coated battery separator is thin or ultrathin. A method for forming a coated battery separator that exhibits the aforementioned properties is also described. The method may include steps of forming a coating and calendering the coating. In some embodiments, calendering is performed on a dried coating. In some embodiments, the coating is or includes a ceramic coating, a polymer coating, a sticky coating, a shutdown coating, or combinations thereof.

The problems or issues faced by typical larger SSE batteries are solved by providing an interface or interfacial layer at least between the anode, which comprises Li or Na, and the solid state electrolyte (SSE). In some other embodiments, an interfacial layer may be provided between the anode, which comprises Li or Na, and the SSE, and an interface or interfacial layer may also be provided between the cathode and the SSE. In at least selected embodiments, aspects or objects, the interfacial layer may act as a shock absorber between a SSE (e.g., a sulfide glass SSE) and an anode material that is soft compared to the SSE (e.g., Li metal). In other embodiments, the interfacial layer may act as a shock absorber between the SSE and a cathode material that is softer than the SSE. In at least certain embodiments, the interfacial layer may improve ionic conductance between the anode and the SSE and/or the SSE and the cathode. In at least certain selected embodiments, the interfacial layer may prevent or deter lithium deposition and dendrite growth at the interface between the anode and the SSE. Interface defects at the interface between the anode and the SSE may allow lithium deposition and dendrite growth. The dendrites may continue to grow through cracks in the SSE causing a short, which is a safety issue. The inventive interfacial layer between the anode and the SSE may prevent or deter this. In at least some embodiments, the interfacial layer may be a porous polymer layer filled with liquid electrolyte and may improve ionic conductance between the anode and the SSE and/or the SSE and the cathode. In certain embodiments, the anode interface or interfacial layer may be a porous polymer layer filled with liquid electrolyte. In some embodiments, the cathode interface or interfacial layer may be a porous polymer layer filled with liquid, gel or polymer electrolyte.