UV-Triggered Composite Gel Membrane with High Solid Electrolyte Concentration

Abstract

A battery cell comprises A anode electrodes, C cathode electrodes, and S separators arranged between the A anode electrodes and the C cathode electrodes, where A, C, and S are integers greater than one. The S separators comprise a composite gel membrane cured in situ using ultraviolet light, a polymer, a solid electrolyte comprising more than 20 wt% of the composite gel membrane, an initiator, and a liquid electrolyte.

Description

INTRODUCTION

[0001] The information provided in this section is intended to provide a general context for the disclosure. Work by the currently named inventors, to the extent described in this section, as well as aspects of the description that may not be prior art at the time of filing, are neither expressly nor impliedly acknowledged as prior art over the present disclosure.

[0002] The present disclosure relates to battery cells and, more particularly, to battery cells comprising composite gel membranes.

[0003] Electric vehicles (EVs), such as battery electric vehicles (BEVs), hybrid vehicles, and / or fuel cell vehicles, comprise one or more electric machines and a battery system comprising one or more battery cells, modules, and / or packs. A power control system is used to control the charging and / or discharging of the battery system during charging and / or driving. SUMMARY

[0004] A battery cell comprises A anode electrodes, C cathode electrodes, and S separators disposed between the A anode electrodes and the C cathode electrodes, where A, C, and S are integers greater than one. The S separators comprise a composite gel membrane cured in situ using ultraviolet light, and a polymer, a solid electrolyte comprising greater than 20 wt.% of the composite gel membrane, an initiator, and a liquid electrolyte.

[0005] In other features, the polymer comprises 5 wt% to 30 wt% of the composite gel membrane, the solid electrolyte comprises 20 wt% to 90 wt% of the composite gel membrane, the initiator comprises 0.1 wt% to 0.25 wt% of the composite gel membrane, and the liquid electrolyte comprises 10 wt% to 80 wt% of the composite gel membrane. The polymer comprises 8 wt% to 15 wt% of the composite gel membrane, the solid electrolyte comprises 35 wt% to 60 wt% of the composite gel membrane, the liquid electrolyte comprises 10 wt% to 15 wt% of the composite gel membrane, and the initiator comprises 0.1 wt% to 0.25 wt% of the composite gel membrane.

[0006] In other features, the initiator is selected from a group consisting of a Norish Type 1 initiator and a Norish Type 2 initiator. The liquid electrolyte comprises one or more solvents and one or more lithium salts. The liquid electrolyte further comprises a solid electrolyte interfacial additive selected from a group consisting of vinylene carbonate (VC), vinylethylene carbonate (VEC), butylene carbonate (BC), fluoroethylene carbonate (FEC), 1,3-propanesultone (PS), ethylene sulfite (ES), ethylene sulfate (DTD), and combinations thereof.

[0007] In other features, the one or more lithium salts have a concentration greater than or equal to 0.8 M / L. The one or more solvents are selected from a group consisting of ethylene carbonate (EC), dimethyl carbonate (DMC), gamma-butyrolactone (GBL), propylene carbonate (PC), ethyl methyl carbonate (EMC), diethyl carbonate (DEC), and combinations thereof. The polymer is selected from a group consisting of polyethylene oxide (PEO), polyvinylidene fluoride (PVDF), polyvinylidene fluoride-hexafluoropropylene (PVDF-HFP), polypropylene oxide (PPO), polyacrylonitrile (PAN), polymethacrylonitrile (PMAN), polymethyl methacrylate (PMMA), their corresponding oligomers and copolymers, and combinations thereof.

[0008] In other features, the solid electrolyte is selected from a group consisting of oxide-based solid electrolytes, metal-doped or aliovalent-substituted oxide-based electrolytes, sulfide-based electrolytes, nitride-based electrolytes, hydride-based electrolytes, halide-based electrolytes, borate-based electrolytes, and combinations thereof.

[0009] A method for making a free-standing composite gel membrane for a battery cell comprises providing a polymer film; delivering a composite gel membrane slurry comprising a polymer, a solid electrolyte comprising greater than 20% by weight of the composite gel membrane, and an initiator onto the polymer film; compressing the slurry and polymer film between first and second rollers; and exposing the slurry to ultraviolet (UV) light for a predetermined period of time at a predetermined wavelength to polymerize the polymer.

[0010] In other features, at least one of the first and second rollers comprises a radially outer surface comprising one of rubber and plastic. The predetermined time period is in a range of 30 to 600 s. The predetermined wavelength is in a range of 10 to 400 nm. The energy of the UV light is in a range of 0.5 J / cm3 to 3 J / cm3. The polymer comprises 5 wt% to 30 wt% of the composite gel membrane, the solid electrolyte comprises 20 wt% to 90 wt% of the composite gel membrane, and the initiator comprises 0.1 wt% to 1.0 wt% of the composite gel membrane.

[0011] In other features, the polymer is selected from a group consisting of polyethylene oxide (PEO), polyvinylidene fluoride (PVDF), polyvinylidene fluoride-hexafluoropropylene (PVDF-HFP), polypropylene oxide (PPO), polyacrylonitrile (PAN), polymethacrylonitrile (PMAN), polymethyl methacrylate (PMMA), their corresponding oligomers and copolymers, and combinations thereof. In other features, the solid electrolyte is selected from a group consisting of oxide-based solid electrolytes, metal-doped or aliphatic-substituted oxide-based electrolytes, sulfide-based electrolytes, nitride-based electrolytes, hydride-based electrolytes, halide-based electrolytes, borate-based electrolytes, and combinations thereof.

[0012] A method for manufacturing a free-standing composite gel membrane and separator for a battery cell comprises providing an electrode; delivering a composite gel membrane slurry comprising a polymer, a solid electrolyte comprising greater than 20% by weight of the composite gel membrane, and an initiator onto the electrode; compressing the slurry and electrode between first and second rollers; and exposing the slurry to ultraviolet (UV) light for a predetermined period of time at a predetermined wavelength to polymerize the polymer.

[0013] In other features, at least one of the first and second rollers includes a radially outer surface comprising one of rubber and plastic. The predetermined time period is in a range of 30 to 600 s. The predetermined wavelength is in a range of 10 to 400 nm. The energy of the UV light is in a range of 0.5 J / cm3 to 3 J / cm3.

[0014] In other features, the polymer comprises 5 wt% to 30 wt% of the composite gel membrane, the solid electrolyte comprises 20 wt% to 90 wt% of the composite gel membrane, and the initiator comprises 0.1 wt% to 1.0 wt% of the composite gel membrane. The polymer is selected from a group consisting of polyethylene oxide (PEO), polyvinylidene fluoride (PVDF), polyvinylidene fluoride-hexafluoropropylene (PVDF-HFP), polypropylene oxide (PPO), polyacrylonitrile (PAN), polymethacrylonitrile (PMAN), polymethyl methacrylate (PMMA), and their corresponding oligomers and copolymers. In other features, the solid electrolyte is selected from a group consisting of oxide-based solid electrolytes, metal-doped or aliovalent-substituted oxide-based electrolytes, sulfide-based electrolytes, nitride-based electrolytes, hydride-based electrolytes, halide-based electrolytes, borate-based electrolytes.

[0015] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are provided for purposes of illustration only and are not intended to limit the scope of the disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present disclosure will be more fully understood from the detailed description and the accompanying drawings, in which: Fig. 1 is a side cross-sectional view of an example of a monopolar battery cell including cathode electrodes, anode electrodes, and separators disposed within a battery cell casing according to the present disclosure; Fig. 2 is a side cross-sectional view of an example of a bipolar battery cell including cathode electrodes, anode electrodes, and separators disposed within a battery cell casing according to the present disclosure; Fig. 3 is a more detailed side cross-sectional view of an example of a monopolar battery cell including cathode electrodes, anode electrodes, and separators disposed within a battery cell casing according to the present disclosure; Fig. 4 is a more detailed side cross-sectional view of an example of a bipolar battery cell including cathode electrodes, anode electrodes, and separators disposed within a battery cell casing according to the present disclosure; Fig. 5 illustrates an example of a method for making a freestanding composite gel membrane according to the present disclosure; and Fig. 6 illustrates an example of a method for fabricating a freestanding electrode having a composite gel membrane according to the present disclosure.

[0017] Reference symbols may be reused in the drawings to identify similar and / or identical elements. DETAILED DESCRIPTION

[0018] Although battery cells with composite gel membranes (CGMs) according to the present disclosure are illustrated in the context of electric vehicles, the battery cells with CGMs may be used in stationary applications and / or other applications.

[0019] Freestanding gel membranes can be used as separators for solid-state batteries (SSBs). Gel membranes help improve layer-to-layer interfacial contact. However, random defects in the gel membrane can lead to internal short circuits, especially when the thickness of the gel membrane is reduced to increase energy density. Using separate layers enclosing the solid electrolyte and the gel membrane increases the thickness and reduces performance.

[0020] The incorporation of solid electrolytes (SEs) into gel membranes enables optimized reliability. However, fabricating composite gel membranes with high SE concentrations and low thicknesses remains challenging due to the high viscosity of precursor solutions. The viscosity of precursor solutions used to coat CGMs increases dramatically with increasing SE concentration. The high viscosity of the precursor solutions complicates their application in film-coating processes. For example, a gel precursor with 15 wt% SE has a viscosity of 700 MPas, a gel precursor with 27 wt% SE has a viscosity of 1200 MPas, and a gel precursor with 41 wt% SE has a viscosity of 16,800 MPas.

[0021] In some examples, composite gel membranes (CGMs) according to the present disclosure comprise a solid electrolyte (SE) having a concentration greater than 40 wt. %, a polymer, an initiator, and a liquid electrolyte. The composite gel membrane is triggered by a process induced using ultraviolet (UV) light. Freestanding CGMs and / or freestanding electrodes containing the CGMs improve the performance of solid-state battery cells. Additionally, the likelihood of short circuits is significantly reduced using CGMs according to the present disclosure.

[0022] The polymers formed during UV in situ polymerization serve as both the scaffold for the gel electrolytes and the binding materials for the CGMs. In some examples, no processing solvents (e.g., N-methyl-2-pyrrolidone (NMP)) or heating chambers are required. As a result, battery cells using the CGMs according to the present disclosure have lower manufacturing costs and higher efficiency than other comparable battery cells.

[0023] With reference now to Fig. 1, a monopolar battery cell 10 comprises C cathode electrodes 20, A anode electrodes 40, and S separators 32 arranged in a predetermined order in a battery cell stack 12 positioned within a housing 50, where C, S, and A are integers greater than zero. The S separators 32 comprise composite gel membranes as described herein.

[0024] The C cathode electrodes 20-1, 20-2, ..., and 20-C comprise a layer 24 of active cathode material disposed on one or both sides of a cathode current collector 26. The A anode electrodes 40-1, 40-2, ..., and 40-A comprise layers 42 of active anode material disposed on one or both sides of the anode current collector 46.

[0025] In some examples, the anode active material layers 42 and / or the cathode active material layers 24 are freestanding electrodes that are respectively disposed adjacent to (or attached to) the cathode current collectors 26 and / or the anode current collectors 46. In some examples, the anode active material layers 42 and / or the cathode active material layers 24 include coatings comprising one or more active materials, one or more conductive fillers / additives, and / or one or more binder materials applied to the current collectors.

[0026] In some examples, the cathode current collectors 26 and / or the anode current collectors 46 comprise foil, mesh, or expanded metal. In some examples, the cathode current collectors 26 and / or the anode current collectors 46 are made of one or more materials selected from a group consisting of copper, stainless steel, brass, bronze, zinc, aluminum, and alloys thereof. The outer tabs 28, 48 can be connected to the current collectors of the anode electrodes and cathode electrodes on the same or opposite sides of the battery stack. The outer tabs 28, 48 are connected to terminals of the battery cells.

[0027] With reference now to Fig. 2, a battery cell 100 includes C cathode electrodes 120, A anode electrodes 140, and S separators 132 arranged in a predetermined order in a stack 112 positioned within a housing 150. The S separators 132 comprise composite gel membranes as described herein.

[0028] The C cathode electrodes 120-1, 120-2, ..., and 120-C comprise layers 124 of active cathode material disposed on a cathode current collector 126 of a bipolar current collector 125. The A anode electrodes 140-1, 140-2, ..., and 140-A comprise layers 142 of active anode material disposed on an anode current collector 146 of the bipolar current collector 125. In some examples, the cathode current collector 126 of the bipolar current collector 125 comprises aluminum foil, and the anode current collector 146 of the bipolar current collector 125 comprises copper foil, although other materials may be used.

[0029] In some examples, the anode active material layers 142 and / or the cathode active material layers 124 are freestanding electrodes disposed adjacent to (or attached to) the bipolar current collectors 125. In some examples, the anode active material layers 142 and / or the cathode active material layers 124 include coatings comprising one or more active materials, one or more conductive fillers / additives, and / or one or more binder materials applied to the anode or cathode layers of the current collectors. In some examples, the battery cells and / or electrodes are manufactured by applying a slurry to coat the current collectors in a roll-to-roll process.

[0030] With reference now to Fig. Figure 3 illustrates an example of the monopolar battery cell 210. The active cathode material layer 24 comprises the active cathode material 210 and the solid electrolyte 212. The S separators 32 comprise a composite gel membrane 220. The active anode material layer 42 comprises the active anode material 230 and the solid electrolyte 232.

[0031] With reference now to Fig. Figure 4 shows an example of the bipolar battery cell 210. The active cathode material layer 124 comprises the active cathode material 210 and the solid electrolyte 212. The S separators 132 comprise the composite gel membrane 220. The active anode material layer 142 comprises the active anode material 230 and the solid electrolyte 232.

[0032] In some examples, the composite gel membrane 220 is a freestanding composite gel membrane comprising a polymer, a solid electrolyte, a liquid electrolyte, and / or an initiator. In some examples, the polymer comprises 5 wt% to 30 wt% of the composite gel membrane, the solid electrolyte comprises 20 wt% to 90 wt% of the composite gel membrane, the liquid electrolyte comprises 10 wt% to 80 wt% of the composite gel membrane, and the initiator comprises 0.1 wt% to 1.0 wt% of the composite gel membrane.

[0033] In some examples, the polymer comprises 8 wt% to 15 wt% of the composite gel membrane, the solid electrolyte comprises 35 wt% to 60 wt% of the composite gel membrane, the liquid electrolyte comprises 10 wt% to 55 wt% of the composite gel membrane, and the initiator comprises 0.1 wt% to 0.25 wt% of the composite gel membrane.

[0034] In some examples, the polymer is selected from a group consisting of polyethylene oxide (PEO), polyvinylidene fluoride (PVDF), polyvinylidene fluoride-hexafluoropropylene (PVDF-HFP), polypropylene oxide (PPO), polyacrylonitrile (PAN), polymethacrylonitrile (PMAN), polymethyl methacrylate (PMMA), their corresponding oligomers and copolymers, and combinations thereof.

[0035] In some examples, the solid electrolyte is selected from a group consisting of oxide-based solid electrolytes, metal-doped or aliovalent-substituted oxide-based electrolytes, sulfide-based electrolytes, nitride-based electrolytes, hydride-based electrolytes, halide-based electrolytes, borate-based electrolytes, and combinations thereof.

[0036] Examples of oxide-based electrolytes include garnet-like (e.g. Li7La3Zr2O 12 ). Perovskite type (e.g. Li 3x La 2 / 3-x TiO3), NASICON type (e.g. Li 1,4 Al 0,4 Ti1,6 (PO4)3 and Li 1+x Al x Ge 2-x (PO4)3), LISICON type (e.g. Li 2+2x Zn 1-x GeO4), and combinations thereof.

[0037] In some examples, low-cost electrolytes such as aluminum oxide Al2O3 or aluminum oxide hydroxide AlO(OH) are used.

[0038] Examples of metal-doped or aliovalently substituted oxide-based electrolytes include Al (or Nb)-doped Li7La3Zr2O 12 , Sb-doped Li7La3Zr2O 12 , Gas-substituted Li7La3Zr2O 12 , Cr- and V-substituted LiSn2P3O 12 and Al-substituted perovskite, Li 1+x+y Al x Ti 2-x Si y P 3-y O 12 , and combinations thereof.

[0039] Examples of sulfide-based electrolytes include Li2S-P2S5 system, Li2S-P2S5-MOx system, Li2S-P2S5-MS x -System, LGPS (Li 10 GeP2S 12 ), Thio-LISICON (Li 3,25 Ge 0,25 P0,75 S4), Li 3,4 Yes 0,4 P 0,6 S4, Lit 10 GeP2S 11,7 About 0,3 , Lithium-Argyrodite Li6PS5X (X = Cl, Br, oder I), Li 9,54 Yes 1,74 P 1,44 S 11,7 Cl 0,3 , Li 9,6 P3S 12 , Li7P3S 11 , Li9P3S9O3,Li 10,35 Ge 1,35 P 1,65 S 12 , Li 10,35 Yes 1,35 P 1,65 S 12 , Li 9,81 Sn 0,81 P 2,19 S 12 , Li 10 (If 0,5 Ge 0,5 )P2S 12 , Li 10 (Ge 0,5 Sn 0,5 )P2S 12 , Li 10 (If 0,5 Sn 0,5 )P2S 12 , Li 3,833 Sn 0,833 As 0,166 S4, LiI-Li4SnS4, Li4SnS4, und Kombinationen davon.

[0040] Examples of nitride-based electrolytes include Li3N, Li7PN4, and LiSi2N3. Examples of hydride-based electrolytes include LiBH4, LiBH4-LiX (X = chlorine (Cl), bromine (Br), or iodine (I)), LiNH2, Li2NH, LiBH4-LiNH2, and Li3AlH6. Examples of halides include LiIl, Li3InCl6, Li2CdCl4, Li2MgCl4, Li2CdI4, Li2ZnI4, and Li3OCl. Examples of borate-based electrolytes include Li2B4O7, Li2O-B2O3-P2O5, and combinations thereof.

[0041] In some examples, the liquid electrolyte comprises one or more solvents and one or more lithium salts. In some examples, the lithium salts have a concentration greater than or equal to 0.8 M / L. In some examples, the one or more solvents are selected from a group consisting of ethylene carbonate (EC), dimethyl carbonate (DMC), gamma-butyrolactone (GBL), propylene carbonate (PC), ethyl methyl carbonate (EMC), diethyl carbonate (DEC), and combinations thereof.

[0042] In some examples, the lithium salts are selected from a group consisting of LiTFSI, LIFSI, LiBETI, LiPF6, LiBOB, LiDFOB, LiBF4, LiAsF6, LiClO4, LiTfO, and combinations thereof.

[0043] In some examples, the liquid electrolyte may further comprise one or more solid electrolyte interfacial additives (SEI). In some examples, the SEI additive is selected from a group consisting of vinylene carbonate (VC), vinylethylene carbonate (VEC), butylene carbonate (BC), fluoroethylene carbonate (FEC), 1,3-propane sultone (PS), ethylene sulfite (ES), ethylene sulfate (DTD), and combinations thereof.

[0044] In some examples, the initiator is selected from a group consisting of a Norish Type 1 initiator and a Norish Type 2 initiator. In some examples, the Norish Type 1 initiator is selected from a group consisting of 2,4,6-trimethylbenzoyldiphenylphosphine oxide (TPO), hydroxyacetophenone (HAP), Irgacure 1173, Irgacure 184, Irgacure 369, Irgacure 651, and Irgacure 907. In some examples, the Norish Type 2 initiator is selected from a group consisting of benzophenone, 2-isopropylthioxanthone, 4-methylbenzophenone, ethyl 4-dimethylaminobenzoate, 4-chlorobenzophenone, and combinations thereof.

[0045] With reference now to Fig. 5 illustrates a method 300 for fabricating a freestanding composite gel membrane. A roll 310 of polymer film 312 is fed between a pair of rollers 320 and 321. A dispenser 326 delivers a slurry 328 for the composite gel membrane onto a surface of the polymer film 312. Rollers 320 and 321 compress the slurry. In some examples, a roll 327 delivers an additional polymer film 328, which is fed by a roller 327 onto a top surface of the slurry. The additional polymer film prevents evaporation of liquid electrolyte. After passing through rollers 320 and 321, the film and slurry pass through a UV chamber 340 for UV curing. After curing and cooling, a freestanding composite gel membrane 344 is collected on a roll 350. In some examples, the polymer film 312 is removed prior to fabricating the battery cell with the composite gel membrane.

[0046] In some examples, one or both of rollers 320 and 321 are other than the metal-based rollers typically used in a roll-to-roll process. In some examples, one or both of rollers 320 and 321 comprise soft materials such as rubber or plastic (e.g., PP, PTFE). In some examples, a radially outer surface of one of rollers 320 and 321 has a metal surface.

[0047] In some examples, one or both of the rollers 320 and 321 have a core-shell structure. A core 322 is made of a rigid material such as metal (e.g., stainless steel), and a radially outer surface 323 of the core 322 comprises a softer material than metal (e.g., rubber, plastic (e.g., PP, PTFE)). In some examples, the rollers 320 and 321 have a diameter in a range of 20 mm to 500 mm. In some examples, the rollers 320 and 321 have a diameter in a range of 50 mm to 200 mm. In some examples, the roller pressure is in a contact pressure range of 0.01 T to 3.0 T. In some examples, the roller pressure is in a contact pressure range of 0.05 T to 0.5 T.

[0048] With reference now to Fig.6 illustrates a method 400 for fabricating a freestanding electrode comprising a composite gel membrane. A roll 410 comprising a freestanding electrode 412 (e.g., anode or cathode electrode) is fed between a pair of rollers 320 and 321. Dispenser 326 delivers a slurry 328 for the composite gel membrane onto a surface of the electrode 412. Rollers 320 and 321 compress the slurry 328 and the electrode 412. In some examples, roller 327 delivers the additional polymer film 327, which is fed by roller 327 onto a top surface of the slurry. The additional polymer film prevents evaporation of liquid electrolyte. After passing through the rollers 320 and 321, the electrode 412 and the compressed slurry 328 pass through a UV chamber 340 for UV polymerization.After UV polymerization and cooling, a freestanding electrode 444 comprising a composite gel membrane is collected on the roll 350.

[0049] In some examples, UV curing is performed at a wavelength in a range of 100 to 400 nm. In some examples, UV curing is performed at a wavelength in a range of 340 to 380 nm (e.g., 365 nm). In some examples, the UV chamber provides energy in a range of 0.25 J / cm2 to 3 J / cm2. In some examples, the UV chamber provides energy in a range of 0.5 J / cm2 to 1.5 J / cm2. In some examples, the UV curing time is in a range of 30 s to 600 s. In some examples, the UV curing time is in a range of 50 s to 120 s.

[0050] In some examples, the polymer film comprises a non-adhesive plastic. In some examples, the non-adhesive plastic is selected from a group consisting of PET, PP, PMMA, PTFE, etc.

[0051] In some examples, the electrodes have a width ranging from 50 mm to 500 mm. In some examples, the polymers in the CGMs comprise small molecules. For example, the polymers in the CGMs comprise monomers or oligomers (e.g., those with a lower viscosity) that are dissolved in the CGM slurry and crosslinked during UV polymerization.

[0052] In some examples, the CGMs can be fabricated as a freestanding separator (on a removable film) or on freestanding electrodes (e.g., cathode and / or anode electrodes). Eliminating the heating and / or solvent recycling system eliminates processing solvents and consumes less electricity. The process for forming the freestanding CGMs or freestanding electrodes with the CGMs is relatively rapid (e.g., less than 10 minutes), enabled by UV polymerization.

[0053] The foregoing description is merely illustrative and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure may be implemented in a variety of forms. Therefore, while this disclosure includes specific examples, the true scope of the disclosure should not be limited thereto, since other changes will become apparent after studying the drawings, the patent specification, and the following claims. It is understood that one or more steps within a method may be performed in a different order (or simultaneously) without altering the principles of the present disclosure.Furthermore, although the embodiments are each described above as having specific features, any one or more of these features described with respect to one embodiment of the disclosure may be implemented and / or combined with features of any of the other embodiments, even if this combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and interchanging one or more embodiments remains within the scope of this disclosure.

[0054] Spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected," "engaging," "coupled," "adjacent," "beside," "on top of," "over," "below," and "disposed." Where a relationship between first and second elements is not explicitly described as "direct" in the above disclosure, that relationship may be a direct relationship, with no other intervening elements between the first and second elements, or an indirect relationship, with one or more intervening elements (either spatial or functional) between the first and second elements.As used herein, the term “A, B and / or C” should be construed as logical (A ORed with B ORed with C) using a non-exclusive logical OR and should not be understood as “at least one of A, at least one of B and at least one of C”.

[0055] In the figures, the direction of an arrow, as indicated by the arrowhead, generally illustrates the flow of information (such as data or instructions) of interest to the illustration. For example, if element A and element B exchange a plurality of pieces of information, but the information sent from element A to element B is relevant to the illustration, the arrow may point from element A to element B. This unidirectional arrow does not imply that no other information is sent from element B to element A. Further, for information sent from element A to element B, element B may send requests or acknowledgments for the information to element A.

Claims

[1] Battery cell, comprising: A anode electrodes; C cathode electrodes; and S separators arranged between the anode electrodes A and the cathode electrodes C, where A, C and S are integers greater than 1, wherein the S separators comprise a composite gel membrane cured in-situ using ultraviolet light, and a polymer, a solid electrolyte comprising greater than 20 wt% of the composite gel membrane, an initiator, and a liquid electrolyte. [2] The battery cell of claim 1, wherein the polymer comprises 5 wt% to 30 wt% of the composite gel membrane, the solid electrolyte comprises 20 wt% to 90 wt% of the composite gel membrane, the initiator comprises 0.1 wt% to 0.25 wt% of the composite gel membrane, and the liquid electrolyte comprises 10 wt% to 80 wt% of the composite gel membrane. [3] The battery cell of claim 1, wherein the polymer comprises 8 wt% to 15 wt% of the composite gel membrane, the solid electrolyte comprises 35 wt% to 60 wt% of the composite gel membrane, the liquid electrolyte comprises 10 wt% to 15 wt% of the composite gel membrane, and the initiator comprises 0.1 wt% to 0.25 wt% of the composite gel membrane. [4] The battery cell of claim 1, wherein the initiator is selected from a group consisting of a Norish Type 1 initiator and a Norish Type 2 initiator. [5] The battery cell of claim 1, wherein the liquid electrolyte comprises one or more solvents and one or more lithium salts. [6] The battery cell of claim 5, wherein the liquid electrolyte further comprises a solid electrolyte interfacial additive selected from a group consisting of vinylene carbonate (VC), vinylethylene carbonate (VEC), butylene carbonate (BC), fluoroethylene carbonate (FEC), 1,3-propanesultone (PS), ethylene sulfite (ES), ethylene sulfate (DTD), and combinations thereof. [7] The battery cell of claim 5, wherein the one or more lithium salts have a concentration greater than or equal to 0.8 M / L. [8] The battery cell of claim 5, wherein the one or more solvents are selected from a group consisting of ethylene carbonate (EC), dimethyl carbonate (DMC), gamma-butyrolactone (GBL), propylene carbonate (PC), ethyl methyl carbonate (EMC), diethyl carbonate (DEC), and combinations thereof. [9] The battery cell of claim 1, wherein the polymer is selected from a group consisting of polyethylene oxide (PEO), polyvinylidene fluoride (PVDF), polyvinylidene fluoride-hexafluoropropylene (PVDF-HFP), polypropylene oxide (PPO), polyacrylonitrile (PAN), polymethacrylonitrile (PMAN), polymethyl methacrylate (PMMA), their corresponding oligomers and copolymers, and combinations thereof. [10] The battery cell of claim 1, wherein the solid electrolyte is selected from a group consisting of oxide-based solid electrolytes, metal-doped or aliovalent-substituted oxide-based electrolytes, sulfide-based electrolytes, nitride-based electrolytes, hydride-based electrolytes, halide-based electrolytes, borate-based electrolytes, and combinations thereof.

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