This technology introduces a scalable dry-processing approach for manufacturing ultrathin ceramic membranes combined with a polymer layer to form a hybrid separator or electrolyte for electrochemical cells. Conventional ceramic components are often thick, brittle, and difficult to integrate into modern battery architectures. The new process creates thinner, mechanically resilient membranes while avoiding liquid solvents and complex drying steps. The resulting hybrid structure helps control unwanted chemical migration within cells while maintaining ion transport and stable electrode interfaces. The approach supports higher-throughput manufacturing and improved durability of electrochemical systems used in large-scale power storage and other advanced battery applications.
Description
Researchers at Oak Ridge National Laboratory developed a solvent-free dry-processing method for producing ultrathin ceramic membranes that can be combined with a single-ion-conducting polymer layer to create a ceramic–polymer hybrid separator. The fabrication approach uses mechanical mixing and shear processing to form a cohesive ceramic composite that can be shaped into thin films through continuous manufacturing techniques.
Unlike conventional slurry-based processing, this dry route eliminates liquid solvents and associated evaporation steps, simplifying manufacturing and reducing processing complexity. The resulting membranes are significantly thinner and more mechanically compliant than traditional pressed ceramic pellets, enabling easier integration with electrode materials.
The ceramic layer functions as a selective barrier that helps limit the movement of unwanted chemical species inside electrochemical cells, while the polymer layer provides interfacial flexibility and supports efficient ion transport. Together, these layers form a hybrid membrane that balances selectivity, durability, and manufacturability. The process is compatible with scalable production approaches and may enable lighter and more cost-aligned components for advanced sodium-based battery systems and other electrochemical technologies.
Benefits
- Solvent-free manufacturing approach that simplifies processing and reduces production complexity
- Ultrathin, mechanically resilient membranes that are easier to integrate into electrochemical systems
- Improved control of unwanted species transport within battery cells
- Compatible with scalable continuous manufacturing methods
Applications and Industries
- Battery and electrochemical cell manufacturing
- Grid reliability and large-scale power storage technologies
- Advanced materials manufacturing
- Industrial membrane and separator production
Contact
To learn more about this technology, email [email protected] or call 865-574-1051.
Researchers
Contact
To learn more about this technology, email [email protected] or call 865-574-1051.