Ceramic nanofiber separators

Abstract

Provided herein are ceramic nanofibers and processes for preparing the same. In specific examples, provided herein are ceramic nanofiber mats for use as separators in batteries, particularly lithium ion batteries.

What is claimed is: 
     
         1 . A battery separator comprising a nanofiber mat, the nanofiber mat comprising at least one nanofiber, the at least one nanofiber comprising at least one ceramic material. 
     
     
         2 . The battery separator of  claim 1 , wherein the at least one nanofiber comprises a continuous matrix of ceramic material. 
     
     
         3 . The battery separator of  claim 1 , wherein the separator comprises at least one ceramic material and at least one polymer material. 
     
     
         4 . The battery separator of any  claim 1 , wherein the nanofiber is a nanocomposite nanofiber, comprising at least two materials. 
     
     
         5 . The battery separator of  claim 4 , wherein the nanocomposite nanofiber comprises at least two ceramic materials. 
     
     
         6 . The battery separator of  claim 5 , wherein the at least two ceramic materials are coaxially layered. 
     
     
         7 . The battery separator of  claim 4 , wherein the nanocomposite nanofiber comprises at least one ceramic material and at least one polymer material. 
     
     
         8 . The battery separator of  claim 7 , wherein the ceramic material(s) and polymer material(s) are coaxially layered. 
     
     
         9 . The battery separator of  claim 7 , wherein the ceramic material(s) and polymer material(s) form an integrated nanofiber matrix. 
     
     
         10 . The battery separator of  claim 7 , wherein the at least one ceramic material forms a continuous nanofiber matrix. 
     
     
         11 . The battery separator of  claim 4 , wherein the nanocomposite nanofiber comprises a first ceramic material as a core material and a second ceramic material as a sheath material, the sheath material at least partially surrounding the core material. 
     
     
         12 . The battery separator of  claim 5 , wherein the at least two ceramic materials are independently selected from the group consisting of silica, alumina, zirconia, beryllia, ceria, titania, barium titanate, and strontium titanate. 
     
     
         13 . The battery separator of  claim 3 , wherein the polymer material is PAN, polyalkeneoxide (e.g., polyethylene oxide or polypropylene oxide), polyalkylene (e.g., polyethylene or polypropylene), PVA, or a polyacrylate (e.g., polyacrylic acid or PMMA). 
     
     
         14 . The battery separator of  claim 1 , wherein the at least one nanofiber is mesoporous. 
     
     
         15 . The battery separator of  claim 1 , wherein the at least one nanofiber comprises a mesoporous ceramic matrix. 
     
     
         16 . The battery separator of  claim 1 , wherein the porosity of the nanofiber mat is at least 10%. 
     
     
         17 . The battery separator of  claim 1 , wherein the nanofiber mat comprises at least 50% by weight of ceramic material. 
     
     
         18 . The battery separator of  claim 1 , wherein the at least one nanofiber has an average diameter of less than 1 micron (e.g., 100 nm to 1 micron, or 200 nm to 1 micron). 
     
     
         19 . The battery separator of  claim 1 , wherein the at least one nanofiber has an average aspect ratio of at least 100 (e.g., at least 10,000). 
     
     
         20 . A battery comprising the battery separator of  claim 1 , wherein the battery is a lithium ion battery. 
     
     
         21 . (canceled)