Development of an advanced dimensionally stable separator for rechargeable lithium-metal disulfide batteries

A unique separator which is AlN powder prefused to impart dimensional stability has been developed. Cell and battery design is based upon a bipolar configuration. Test samples each having 20-cm² area and having several porosities as well as highly uniform 200-cm² separators have been fabricated. Extensive pulse discharge characterization of the 20-cm² separators has verified excellent cycle life along with maintenance of dimensional stability over both time and deep discharge cycling, and complete inertness to the operating environment. Another added benefit is the separator structure´s high thermal conductivity to aid with the thermal management of sealed modules. The physical and handling characteristics of these separators, pulse discharge and cycle data including comparisons to the standard MgO powder separator, and the status of the incorporation of the full size separators into bipolar modules are presented