Method of making a passively impact resistant battery

Abstract

A method of making a passively impact resistant battery includes the steps of providing a porous separator material having pores and a surface, and providing a suspension composition including shear thickening enabling particles and a particle suspension solvent for suspending the shear thickening enabling particles. The shear thickening particles have a polydispersity index of no greater than 0.1, an average particle size of in a range of 50 nm to 1 um, and an absolute zeta potential of greater than ±40 mV. The suspension composition is applied to the separator material, wherein a portion of the particles and suspension solvent penetrate the pores. The suspension solvent is evaporated from the separator material. An anode layer and a cathode layer are applied. An electrolyte composition is applied between the anode layer and the cathode layer. The electrolyte composition includes an electrolyte solvent and an electrolyte salt.