Shutdown and non-shutdown separators for electrochemical devices

An electrochemical device, comprising:

• a housing;
• an electrolyte solution disposed within the housing;
• an anode disposed within the electrolyte solution in the housing;
• a cathode disposed within the electrolyte solution in the housing;
• and
• one of a single layer, fire-resistant shutdown separator and a non-shutdown separator disposed within the electrolyte solution in the housing;
• wherein, when used, the single layer, fire resistant shutdown separator comprises a single film, amorphous porous planar cast structure defining curved and rounded-like shaped pores uniformly distributed throughout a sponge-like structure of the single film, amorphous porous planar cast structure providing mechanical strength in both machine and transverse directions, comprising:
• a plurality of polymeric materials comprising at least a first polymeric material having a relatively lower melting point, wherein the first polymeric material comprises a poly(vinylidene fluoride-co-hexafluoropropylene) (PVdF-HFP) copolymer, and a second polymeric material having a relatively higher melting point, wherein the second polymeric material comprises polysulfonamide (PSA);
• and
• a filler material comprising calcium carbonate;
• wherein the filler material has a particle size of between about 0.1 micron and about 1 micron and the amorphous porous planar cast structure has a thickness of between about 10μ and about 100μ, a pore size between about 0.0161 micron and about 1 micron, and a porosity of between about 50% and about 80% forming the single layer, fire-resistant shutdown separator, wherein the separator has a wettability of at least about 167% as measured by a two hour immersion in 1 M LiPF6 solution of ethylene carbonate and dimethyl carbonate (50:50);
• and
• wherein, when used, the non-shutdown separator comprises an amorphous porous planar cast structure defining curved pores uniformly distributed throughout a sponge-like structure providing mechanical strength in both machine and transverse directions, comprising:
• a polymeric material;
• and
• an inorganic particulate filler material;
• wherein the filler material has a particle size of between about 0.1 micron and about 1 micron and the amorphous porous planar cast structure has a thickness of between about 10μ and about 70μ, a pore size between about 0.0161 micron and about 1 micron, and a porosity of between about 60% and about 200%.