Ceramic-coated separators for lithium-containing electrochemical cells and methods of making the same

A method of manufacturing a ceramic-coated substrate for a lithium-containing electrochemical cell, the method comprising:

• admixing a precursor zeolite powder with an aqueous solution comprising lithium hydroxide (LiOH) to form a zeolite slurry;
• exposing the zeolite slurry to a temperature greater than or equal to about 50° C. to less than or equal to about 100° C. for a time greater than or equal to about 6 hours to less than or equal to about 24 hours to form a lithiated-oxide powder, wherein the lithiated-oxide powder comprises one or more lithiated oxides selected from the group consisting of Li2SiO3, LiAlO2, Li2TiO3, LiNbO3, Li3PO4, Li2CrO4, Li2Cr2O7, and combinations thereof;
• admixing the lithiated-oxide powder with a binder selected from the group consisting of:
• carboxymethyl cellulose (CMC), sodium alginate, polyacrylic acid (PAA), styrene-butadiene rubber (SBR), polyvinylidene fluoride (PVdF), and combinations thereof to form a lithiated-oxide slurry;
• disposing the lithiated-oxide slurry onto one or more surfaces of a substrate;
• and
• exposing the lithiated-oxide slurry to a temperature greater than or equal to about 50° C. to less than or equal to about 120° C. for a time greater than or equal to about 6 hours to less than or equal to about 24 hours to form a ceramic coating on the one or more surfaces of the substrate so as to create the ceramic-coated substrate, wherein the lithium-containing electrochemical cell comprising the ceramic-coated separator cycles at temperatures greater than or equal to about 50° C. and has a charge capacity loss of less than or equal to about 25% after 25 cycles of lithiation and delithiation.

A ceramic-coated separator for a lithium-containing electrochemical cell, the ceramic-coated separator comprising:

• a porous substrate;
• and
• a ceramic coating disposed on one or more surfaces of the porous substrate, wherein the ceramic coating comprises one or more lithiated oxides selected from the group consisting of Li2SiO3, LiAlO2, Li2TiO3, LiNbO3, Li3PO4, Li2CrO4, Li2Cr2O7, and combinations thereof and a thickness of greater than or equal to about 5 μm to less than about 10 μm,
• wherein the lithium-containing electrochemical cell comprising the ceramic-coated separator cycles at temperatures greater than or equal to about 50° C. and has a charge capacity loss of less than or equal to about 25% after 25 cycles of lithiation and delithiation.