Battery separators and related methods

Abstract

Battery separators and methods are disclosed. The battery separator may be used in a lithium battery. The separator may include a microporous membrane laminated to a coated nonwoven. The coating may contain a polymer and optionally, a filler or particles. The methods may include the steps of: unwinding the microporous membrane and the nonwoven, laminating the nonwoven and microporous membrane, and coating the nonwoven before or after lamination.

We claim: 
     
         1 . A battery separator for a lithium battery comprising:
 At least one microporous membrane or layer, at least one nonwoven layer or material on at least one side of said microporous membrane, said nonwoven layer being bonded to or laminated on or to said microporous membrane, and wherein at least one of: wherein at least one of said separator, said microporous membrane, and said nonwoven layer including at least one of: at least one ferroelectric polymer, wherein said ferroelectric polymer being selected from the group consisting of polyethylene oxide (PEO), polytetrafluoroethylene (PTFE), polyurethane (PU), polyacrylonitrile (PAN), polymethylmethacrylate (PMMA), polytetraethylene glycol diacrylate, polyvinylidene fluoride (PVDF), co-polymers thereof, and blends containing the foregoing, wherein said ferroelectric polymer being selected from the group consisting of polyvinylidene fluoride (PVDF), co-polymers thereof, and blends containing the foregoing, wherein said polyvinylidene fluoride (PVDF) co-polymer being selected from the group consisting of polyvinylidene fluoride:hexafluoropropylene (PVDF:HFP) and polyvinylidene fluoride:chlorotrifluoroethylene (PVDF:CTFE), at least one filler, wherein said filler being an inert, thermally stable particle, wherein said filler being a ceramic particle selected from the group consisting of silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), boehmite, calcium carbonate (CaCO 3 ), titanium dioxide (TiO 2 ), SiS 2 , SiPO 4 , and mixtures, blends or combinations thereof, wherein said filler being a ceramic particle selected from the group consisting of silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), calcium carbonate (CaCO 3 ), titanium dioxide (TiO 2 ), and mixtures thereof, wherein said filler being a ceramic particle selected from the group consisting of silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), calcium carbonate (CaCO 3 ), and mixtures thereof, wherein said filler having an average particle size in the range of 0.001 micron to 25 microns, most preferably in the range of 0.01 micron to 2 microns, wherein said filler having an average particle size in the range of 0.01 micron to 2 microns, a polymer or polymeric fibers, wherein said polymer or fibers being selected from the group of: polyolefin, polyester, fluoro-polymer, e.g., PVDF, polyamide (eg, nylon), polyaramid (KEVLAR, NOMEX), acrylic, PVC, co-polymers, blends, mixtures or combinations thereof, alone, or with other polymers, wherein said polyester being selected from the group consisting of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polytrimethylene terephthalate (PTT), co-polymers, blends, mixtures or combinations of the foregoing, bicomponent (hetero-fil) fibers, wherein said bicomponent fiber being selected from the group consisting of sheath-core fibers, side-by-side fibers, island-in-the-sea fibers and combinations thereof, wherein said bicomponent fiber having a low melt temperature component and a high melt temperature component, where the low melt component having a melt temperature less than the high melt temperature component, wherein said low melt temperature component being a polyolefin, wherein the polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said high melt temperature component being selected from the group consisting of: polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid (eg, KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein said bicomponent fiber having a polyolefin sheath and a core being made of a polymer selected from the group consisting of: polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid (KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein said bicomponent fiber having a polyethylene sheath and a core being made of a polymer selected from the group consisting of: polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid (KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein said bicomponent fiber having a polyolefin sheath and a polyester core, wherein said bicomponent fiber having a polyethylene sheath and a polyethylene terephthalate (PET) core, a carded nonwoven, a needle-punched nonwoven, an air-laid nonwoven, a wet-laid nonwoven, a spunlaced (hydroentangled) nonwoven, a spunbonded nonwoven, a melt-spun nonwoven, an electro-spun nonwoven, and combinations thereof, staple fibers, and/or continuous filaments, wherein said nonwoven having a thickness of less than 1 mil (25.4 microns), wherein said nonwoven having a thickness of less than 0.5 mil (12.7 microns), wherein said nonwoven having a thickness of less than 0.25 mil (6.4 microns), wherein said nonwoven further comprising a coating, a coating wherein said coating covering a fiber surface of the nonwoven, wherein said coating partially or fully covering a fiber surface of the nonwoven, wherein said coating covering a surface of the nonwoven, wherein said coating partially covering a surface of the nonwoven, wherein said coating fully impregnates into the interior voids of the nonwoven, wherein said coating be made of a ferroelectric polymer, wherein said ferroelectric polymer being selected from the group consisting of polyethylene oxide (PEO), polytetrafluoroethylene (PTFE), polyurethane (PU), polyacrylonitrile (PAN), polymethylmethacrylate (PMMA), polytetraethylene glycol diacrylate, polyvinylidene fluoride (PVDF), co-polymers thereof, and blends containing the foregoing, wherein said ferroelectric polymer being selected from the group consisting of polyvinylidene fluoride (PVDF), co-polymers thereof, and blends containing the foregoing, wherein said polyvinylidene fluoride (PVDF) co-polymer being selected from the group consisting of polyvinylidene fluoride:hexafluoropropylene (PVDF:HFP) and polyvinylidene fluoride:chlorotrifluoroethylene (PVDF:CTFE), wherein said coating further including filler, wherein said filler being blended into the coating before application to said nonwoven, wherein said filler being added onto the coating after application of the coating onto said nonwoven, wherein said filler being an inert, thermally stable particle, wherein said filler being a ceramic particle selected from the group consisting of silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), boehmite, calcium carbonate (CaCO 3 ), titanium dioxide (TiO 2 ), SiS 2 , SiPO 4  and mixtures thereof, wherein said filler being a ceramic particle selected from the group consisting of silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), calcium carbonate (CaCO 3 ), titanium dioxide (TiO 2 ), and mixtures thereof, wherein said filler being a ceramic particle selected from the group consisting of silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), calcium carbonate (CaCO 3 ), and mixtures thereof, wherein said filler having an average particle size in the range of 0.001 micron to 25 microns, most preferably in the range of 0.01 micron to 2 microns, wherein said filler having an average particle size in the range of 0.01 micron to 2 microns, wherein said microporous membrane has a porosity in the range of about 20-80%, wherein said microporous membrane has a porosity in the range of about 28-60%, wherein said microporous membrane has an average pore size in the range of about 0.02 to 2 microns, wherein said microporous membrane has an average pore size in the range of about 0.08 to 0.5 micron, wherein said microporous membrane has a Gurley Number in the range of about 15 to 150 sec, wherein said microporous membrane has a Gurley Number in the range of about 30 to 80 sec, wherein said microporous membrane has a single ply, wherein said single ply being made of a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polyethylene (PE), wherein said microporous membrane has multiple plies, wherein said microporous membrane has two plies, wherein each ply being made of a different polymer, wherein one ply being made of a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polyethylene (PE), wherein another ply being made of a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polypropylene (PP), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polypropylene (PP), wherein one ply being made of a polyethylene-based polymer and another ply being made of a polypropylene-based polymer, wherein said microporous membrane has three plies, wherein at least two ply being made of a different polymer, wherein at least two ply being made of a same polymer, wherein the outer plies being made of the same polymer and the inner ply being made of a different polymer, wherein the same polymer being a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polypropylene (PP), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polypropylene (PP), wherein the different polymer being a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polyethylene (PE), and/or wherein said plies are layered as polypropylene (PP)/polyethylene (PE)/polypropylene (PP); wherein the separator is a laminated or composite separator with said nonwoven layer laminated to said microporous membrane before or after applying a coating to said nonwoven layer, wherein said nonwoven being made polymeric fibers, and the polymer being selected from the group of: polyolefin, polyester, fluoro-polymer, e.g., PVDF, polyamide (eg, nylon), polyaramid (KEVLAR, NOMEX), acrylic, PVC, or other polymers, wherein said polyester being selected from the group consisting of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polytrimethylene terephthalate (PTT), co-polymers of the foregoing, and blends of the foregoing, wherein said nonwoven being made of bicomponent (hetero-fil) fibers, wherein said bicomponent fiber being selected from the group consisting of sheath-core fibers, side-by-side fibers, island-in-the-sea fibers and combinations thereof, wherein said bicomponent fiber having a low melt temperature component and a high melt temperature component, where the low melt component having a melt temperature less than the high melt temperature component, wherein said low melt temperature component being a polyolefin, wherein the polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said high melt temperature component being selected from the group consisting of: polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid (eg, KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein said bicomponent fiber having a polyolefin sheath and a core being made of a polymer selected from the group consisting of: polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid (KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein said bicomponent fiber having a polyethylene sheath and a core being made of a polymer selected from the group consisting of: polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid (KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein said bicomponent fiber having a polyolefin sheath and a polyester core, wherein said bicomponent fiber having a polyethylene sheath and a polyethylene terephthalate (PET) core, wherein said nonwoven being a carded nonwoven, a needle-punched nonwoven, an air-laid nonwoven, a wet-laid nonwoven, a spunlaced (hydroentangled) nonwoven, a spunbonded nonwoven, a melt-spun nonwoven, an electro-spun nonwoven, and combinations thereof, wherein said nonwoven being made of staple fibers, and/or continuous filaments, wherein said nonwoven having a thickness of less than 1 mil (25.4 microns), wherein said nonwoven having a thickness of less than 0.5 mil (12.7 microns), wherein said nonwoven having a thickness of less than 0.25 mil (6.4 microns), wherein said nonwoven further comprising a coating, wherein said coating covering a fiber surface of the nonwoven, wherein said coating partially or fully covering a fiber surface of the nonwoven, wherein said coating covering a surface of the nonwoven, wherein said coating partially covering a surface of the nonwoven, wherein said coating fully impregnates into the interior voids of the nonwoven, wherein said coating be made of a ferroelectric polymer, wherein said ferroelectric polymer being selected from the group consisting of polyethylene oxide (PEO), polytetrafluoroethylene (PTFE), polyurethane (PU), polyacrylonitrile (PAN), polymethylmethacrylate (PMMA), polytetraethylene glycol diacrylate, polyvinylidene fluoride (PVDF), co-polymers thereof, and blends containing the foregoing, wherein said ferroelectric polymer being selected from the group consisting of polyvinylidene fluoride (PVDF), co-polymers thereof, and blends containing the foregoing, wherein said polyvinylidene fluoride (PVDF) co-polymer being selected from the group consisting of polyvinylidene fluoride:hexafluoropropylene (PVDF:HFP) and polyvinylidene fluoride:chlorotrifluoroethylene (PVDF:CTFE), wherein said coating further including filler, wherein said filler being blended into the coating before application to said nonwoven, wherein said filler being added onto the coating after application of the coating onto said nonwoven, wherein said filler being an inert, thermally stable particle, wherein said filler being a ceramic particle selected from the group consisting of silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), calcium carbonate (CaCO 3 ), titanium dioxide (TiO 2 ), SiS 2 , SiPO 4  and mixtures thereof, wherein said filler being a ceramic particle selected from the group consisting of silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), calcium carbonate (CaCO 3 ), titanium dioxide (TiO 2 ), and mixtures thereof, wherein said filler being a ceramic particle selected from the group consisting of silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), calcium carbonate (CaCO 3 ), and mixtures thereof, wherein said filler having an average particle size in the range of 0.001 micron to 25 microns, most preferably in the range of 0.01 micron to 2 microns, wherein said filler having an average particle size in the range of 0.01 micron to 2 microns, wherein said microporous membrane has a porosity in the range of about 20-80%, wherein said microporous membrane has a porosity in the range of about 28-60%, wherein said microporous membrane has an average pore size in the range of about 0.02 to 2 microns, wherein said microporous membrane has an average pore size in the range of about 0.08 to 0.5 micron, wherein said microporous membrane has a Gurley Number in the range of about 15 to 150 sec, wherein said microporous membrane has a Gurley Number in the range of about 30 to 80 sec, wherein said microporous membrane has a single ply, wherein said single ply being made of a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polyethylene (PE), wherein said microporous membrane has multiple plies, wherein said microporous membrane has two plies, wherein each ply being made of a different polymer, wherein one ply being made of a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polyethylene (PE), wherein another ply being made of a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polypropylene (PP), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polypropylene (PP), wherein one ply being made of a polyethylene-based polymer and another ply being made of a polypropylene-based polymer, wherein said microporous membrane has three plies, wherein at least two ply being made of a different polymer, wherein at least two ply being made of a same polymer, wherein the outer plies being made of the same polymer and the inner ply being made of a different polymer, wherein the same polymer being a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polypropylene (PP), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polypropylene (PP), wherein the different polymer being a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polyethylene (PE), and/or wherein said plies are layered as polypropylene (PP)/polyethylene (PE)/polypropylene (PP), and combinations thereof.   
     
     
         2 . The battery separator of  claim 1  wherein said battery separator being a battery separator for a secondary lithium battery, a lithium ion battery, or a lithium polymer battery. 
     
     
         3 . The battery separator of  claim 1  wherein said nonwoven being made polymeric fibers, and the polymer being selected from the group of: polyolefin, polyester, fluoro-polymer, e.g., PVDF, polyamide (eg, nylon), polyaramid (KEVLAR, NOMEX), acrylic, PVC, or other polymers. 
     
     
         4 . The battery separator of  claim 3  wherein said polyester being selected from the group consisting of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polytrimethylene terephthalate (PTT), co-polymers of the foregoing, and blends of the foregoing. 
     
     
         5 . The battery separator of  claim 1  wherein said nonwoven being made of bicomponent (hetero-fil) fibers. 
     
     
         6 . The battery separator of  claim 5  wherein said bicomponent fiber being selected from the group consisting of sheath-core fibers, side-by-side fibers, island-in-the-sea fibers and combinations thereof. 
     
     
         7 . The battery separator of  claim 5  wherein said bicomponent fiber having a low melt temperature component and a high melt temperature component, where the low melt component having a melt temperature less than the high melt temperature component. 
     
     
         8 . The battery separator of  claim 7  wherein said low melt temperature component being selected from the group consisting of: a polyolefin, polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said high melt temperature component being selected from the group consisting of: polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid (eg, KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein said bicomponent fiber having a polyolefin sheath and a core being made of a polymer selected from the group consisting of: polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid (KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein said bicomponent fiber having a polyethylene sheath and a core being made of a polymer selected from the group consisting of: polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid (KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein said bicomponent fiber having a polyolefin sheath and a polyester core, wherein said bicomponent fiber having a polyethylene sheath and a polyethylene terephthalate (PET) core, or combinations thereof. 
     
     
         9 . The battery separator of  claim 1  wherein said nonwoven being a carded nonwoven, a needle-punched nonwoven, an air-laid nonwoven, a wet-laid nonwoven, a spunlaced (hydroentangled) nonwoven, a spunbonded nonwoven, a melt-spun nonwoven, an electro-spun nonwoven, and combinations thereof, wherein said nonwoven being made of staple fibers, and/or continuous filaments, wherein said nonwoven having a thickness of less than 1 mil (25.4 microns), wherein said nonwoven having a thickness of less than 0.5 mil (12.7 microns), wherein said nonwoven having a thickness of less than 0.25 mil (6.4 microns), or combinations thereof. 
     
     
         10 . The battery separator of  claim 1  wherein said nonwoven further comprising a coating. 
     
     
         11 . The battery separator of  claim 10  wherein said coating covering a fiber surface of the nonwoven, wherein said coating partially or fully covering a fiber surface of the nonwoven, wherein said coating covering a surface of the nonwoven, wherein said coating partially covering a surface of the nonwoven, wherein said coating fully impregnates into the interior voids of the nonwoven, or combinations thereof. 
     
     
         12 . The battery separator of  claim 10  wherein said coating being made of a ferroelectric polymer, wherein said ferroelectric polymer being selected from the group consisting of polyethylene oxide (PEO), polytetrafluoroethylene (PTFE), polyurethane (PU), polyacrylonitrile (PAN), polymethylmethacrylate (PMMA), polytetraethylene glycol diacrylate, polyvinylidene fluoride (PVDF), co-polymers thereof, and blends containing the foregoing, wherein said ferroelectric polymer being selected from the group consisting of polyvinylidene fluoride (PVDF), co-polymers thereof, and blends containing the foregoing, wherein said polyvinylidene fluoride (PVDF) co-polymer being selected from the group consisting of polyvinylidene fluoride:hexafluoropropylene (PVDF:HFP) and polyvinylidene fluoride:chlorotrifluoroethylene (PVDF:CTFE), or combinations thereof. 
     
     
         13 . The battery separator of  claim 10  wherein said coating further including filler, wherein said filler being blended into the coating before application to said nonwoven, wherein said filler being added onto the coating after application of the coating onto said nonwoven, wherein said filler being an inert, thermally stable particle, wherein said filler being a ceramic particle selected from the group consisting of silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), calcium carbonate (CaCO 3 ), titanium dioxide (TiO 2 ), SiS 2 , SiPO 4  and mixtures thereof, wherein said filler being a ceramic particle selected from the group consisting of silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), calcium carbonate (CaCO 3 ), titanium dioxide (TiO 2 ), and mixtures thereof, wherein said filler being a ceramic particle selected from the group consisting of silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), calcium carbonate (CaCO 3 ), and mixtures thereof, wherein said filler having an average particle size in the range of 0.001 micron to 25 microns, most preferably in the range of 0.01 micron to 2 microns, wherein said filler having an average particle size in the range of 0.01 micron to 2 microns, or combinations thereof. 
     
     
         14 . The battery separator of  claim 1  wherein said microporous membrane has a porosity in the range of about 20-80%, wherein said microporous membrane has a porosity in the range of about 28-60%, wherein said microporous membrane has an average pore size in the range of about 0.02 to 2 microns, wherein said microporous membrane has an average pore size in the range of about 0.08 to 0.5 micron, wherein said microporous membrane has a Gurley Number in the range of about 15 to 150 sec, wherein said microporous membrane has a Gurley Number in the range of about 30 to 80 sec, wherein said microporous membrane has a single ply, wherein said single ply being made of a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polyethylene (PE), wherein said microporous membrane has multiple plies, wherein said microporous membrane has two plies, wherein each ply being made of a different polymer, wherein one ply being made of a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polyethylene (PE), wherein another ply being made of a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polypropylene (PP), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polypropylene (PP), wherein one ply being made of a polyethylene-based polymer and another ply being made of a polypropylene-based polymer, wherein said microporous membrane has three plies, wherein at least two ply being made of a different polymer, wherein at least two ply being made of a same polymer, wherein the outer plies being made of the same polymer and the inner ply being made of a different polymer, wherein the same polymer being a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polypropylene (PP), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polypropylene (PP), wherein the different polymer being a polyolefin, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being selected from the group consisting of: polyethylene (PE), co-polymers of the foregoing, and blends of the foregoing, wherein said polyolefin being polyethylene (PE), wherein said plies are layered as polypropylene (PP)/polyethylene (PE)/polypropylene (PP), or combinations thereof. 
     
     
         15 . The battery separator of  claim 1 , wherein said separator is a composite or laminate battery separator and is made by the steps of:
 unwinding a nonwoven,   unwinding a microporous membrane,   coating the nonwoven with a coating material, and   laminating the coated nonwoven to the microporous membrane;   
       or, by the steps of:
 unwinding a nonwoven, 
 unwinding a microporous membrane, 
 laminating the nonwoven to the microporous membrane, and 
 coating the nonwoven with a coating material; 
 
       and, wherein the coating material containing a ferroelectric material, wherein the coating material containing a ferroelectric material and a filler, or combinations thereof. 
     
     
         16 . In a battery, cell, pack, or module, the improvement comprising the separator of  claim 1 . 
     
     
         17 . In a device, product, system, or vehicle, the improvement comprising the battery, cell, pack, or module of  claim 16 . 
     
     
         18 . A method of making a laminated battery separator comprising the steps of:
 unwinding a nonwoven,   unwinding a microporous membrane,   coating the nonwoven with a coating material, and   laminating the coated nonwoven to the microporous membrane.   
     
     
         19 . The method of  claim 18  wherein the coating material containing a ferroelectric material and an optional filler. 
     
     
         20 . The method of  claim 18  wherein coating being spraying, dipping, contact coating, and/or brushing the coating material thereon. 
     
     
         21 . A method of making a laminated battery separator comprising the steps of:
 unwinding a nonwoven,   unwinding a microporous membrane,   laminating the nonwoven to the microporous membrane, and   coating the nonwoven with a coating material.   
     
     
         22 . The method of  claim 21  wherein the coating material containing a ferroelectric material and an optional filler. 
     
     
         23 . The method of  claim 21  wherein coating being spraying, dipping, contact coating, and/or brushing the coating material thereon. 
     
     
         24 . A battery separator, battery or method as shown, disclosed and/or described herein.