Battery Electrolytes & Separators

Electrolytes and separators form the ionic transport and safety backbone of lithium-ion batteries. While they represent a smaller fraction of cell mass and cost than electrodes, they are decisive for power capability, fast charging, low-temperature performance, cycle life, and safety. These components are tightly co-optimized with cathode and anode materials, which makes them chemistry- and customer-specific rather than fully interchangeable commodities.

Why electrolytes and separators matter

Electrolytes and separators control how lithium ions move between electrodes and how failure modes are mitigated. Small formulation or material changes can materially affect cell performance and safety margins.

• Electrolytes determine ionic conductivity, voltage stability, and temperature range.
• Separators prevent short circuits while allowing ion transport.
• Both components strongly influence fast-charging behavior and thermal stability.

Battery electrolytes

Electrolytes in EV batteries are typically liquid formulations of lithium salts dissolved in organic solvents, with additives to enhance stability, conductivity, and safety. Solid-state and gel electrolytes are in development to improve safety and enable higher energy densities.

Electrolyte Type	Composition	Advantages	Constraints
Liquid Electrolytes	Lithium hexafluorophosphate (LiPF6) in carbonate solvents	Mature, high ionic conductivity, widely adopted	Flammable; thermal runaway risk; limited voltage window
Gel/Polymer Electrolytes	Polyethylene oxide (PEO), PVDF-based gels	Better mechanical stability; improved safety vs liquids	Lower ionic conductivity; scaling challenges
Solid-State Electrolytes	Sulfide, oxide, or polymer-based solids	Non-flammable; enables lithium-metal anodes; high energy density	Manufacturing complexity; interfacial resistance; cost

Electrolyte performance tradeoffs

• High ionic conductivity vs chemical stability.
• Fast charging vs lithium plating risk.
• Low-temperature performance vs high-temperature durability.

Next-generation electrolytes

Next-generation electrolytes aim to extend voltage window, improve fast-charging performance, and enhance thermal stability while remaining compatible with existing lithium-ion manufacturing lines. Most near-term advances build on liquid electrolyte systems rather than replacing them entirely.

• High-voltage electrolytes — optimized salt and additive systems that support cathodes operating above ~4.3–4.4 V without rapid decomposition
• Fast-charge formulations — additive packages that suppress lithium plating and stabilize the SEI during high-rate charging
• Low-temperature electrolytes — solvent blends designed to maintain ionic conductivity and power delivery in cold environments

Beyond conventional liquids, hybrid approaches are under active development but remain largely pre-commercial for high-volume EV use.

• Gel and semi-solid electrolytes — improve safety and leakage resistance while retaining liquid-like ion transport
• Solid-state-adjacent electrolytes — intermediate systems that bridge current liquid electrolytes and fully solid-state designs

In the near to medium term, electrolyte innovation is expected to be incremental and chemistry-specific, with adoption driven by compatibility with existing cell lines, qualification speed, and total system cost rather than step-change material replacement.

Battery separators

The separator is a microporous polymer membrane that prevents direct contact between anode and cathode while allowing lithium ions to pass through. Separator design directly impacts battery safety, internal resistance, and cycle life.

Separator Type	Material	Advantages	Constraints
Polyolefin Separators	Polyethylene (PE), polypropylene (PP)	Low cost; established supply chain	Limited thermal stability; shrinkage risk under heat
Ceramic-Coated Separators	Polymer base with alumina or ceramic coatings	Improved thermal resistance; enhanced safety	Higher cost; added processing steps
Next-Gen Solid Separators	Glass, oxide, or composite structures	Non-flammable; supports solid-state designs	Not yet commercially scaled; manufacturing challenges

Separator safety role

• Thermal shutdown: pore collapse at elevated temperature can halt ion transport.
• Mechanical integrity: resistance to puncture and dendrite penetration.
• Dimensional stability: critical under high-rate and elevated-temperature operation.

Battery-grade requirements

Electrolytes and separators are qualified as part of a complete cell system rather than in isolation.

• Ultra-low moisture content to prevent electrolyte decomposition.
• Consistent composition and thickness control.
• Long-term chemical compatibility with electrode materials.

Electrolyte manufacturers and plants

The table below lists representative electrolyte production facilities supplying lithium-ion battery manufacturers.

Company / Operator	Facility	Location	Primary products
Capchem	Electrolyte Manufacturing Base	Huizhou, Guangdong, China	Lithium-ion battery electrolytes
Guangzhou Tinci Materials	Electrolyte Production Facilities	China (multiple)	Electrolytes and additives
Mitsubishi Chemical	Battery Electrolyte Plants	Japan	Electrolytes
BASF	Electrolyte Production Lines	Europe	Battery electrolytes

U.S. electrolyte OEMs and plants

Manufacturer	Product	Location
Ampcera	Solid state electrolyte	Tucson, AZ
Aqualith Advanced Materials	Aqueous electrolyte	College Park, MD
BASF	Solvents	Geismar, LA
BrightVolt	Polymer Electrolyte	Newberry , IN
Current Chemicals	Liquid electrolyte	Cleveland, OH
Enchem America	Liquid electrolyte	Commerce, GA
Honeywell International	Liquid electrolyte	Buffalo, NY
Huntsman Petrochemical	Solvents	Conroe, TX
Koura - Orbia	LiFP6	St. Gabriel, LA
Mitsubishi Chemical America	Liquid electrolyte	Memphis, TN
Solvay Specialty Polymers	Liquid electrolyte	Augusta, GA
Soulbrain MI	Liquid electrolyte	Northville, MI
South 8 Technologies	Liquefied gas electrolyte	San Diego, CA

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Separator manufacturers and plants

The table below lists representative separator production facilities worldwide supplying lithium-ion battery manufacturers.

Company / Operator	Facility	Location	Primary products
Asahi Kasei	Hipore Separator Plants	Japan / United States	Lithium-ion battery separators
SK IE Technology	Separator Manufacturing Plants	South Korea / Europe	Battery separators
Toray Industries	Separator Production Facilities	Japan	Battery separators
Entek	Separator Manufacturing Plant	Indiana, United States	Battery separators

U.S. separator OEMs and plants

Manufacturer	Product	Location
Celgard	Separators	Charlotte, NC
Celgard	Separators	Concord, NC
Entek	Separators	Lebanon, OR
Microvast	Separators	Clarksville, TN

Battery support materials

Beyond electrolytes and separators, EV batteries rely on a range of auxiliary materials that stabilize electrodes, enhance conductivity, and maintain mechanical integrity. These include additives that extend cycle life, adhesives that secure cell components, and binders that hold active materials together on current collectors. Though used in small amounts, they are essential for reliable high-volume cell manufacturing.

Material Type	Examples	Function	Constraints
Conductive Additives	Carbon black, carbon nanotubes, graphene	Improve electronic conductivity of electrode mixes	Cost and dispersion challenges; quality consistency
Electrolyte Additives	Vinylene carbonate (VC), fluoroethylene carbonate (FEC)	Form stable SEI layers, reduce gas generation, improve cycle life	Precise formulation control needed; adds cost
Binders	Polyvinylidene fluoride (PVDF), water-based SBR/CMC	Hold active particles to current collectors, enable mechanical integrity	Solvent recovery requirements (NMP for PVDF); sustainability concerns
Adhesives & Sealants	Epoxies, polyurethanes, silicone-based adhesives	Bonding of separator, electrodes, and structural pack elements	Thermal expansion mismatch; chemical stability under cycling
Coatings	Al2O3, TiO2, thin ceramic or polymer films	Surface modification of separators/electrodes to improve stability	Added processing steps; trade-off with cost per kWh

While these materials make up only a few percent of total cell mass, they are crucial enablers of high-energy-density cells and safer fast-charging. Supply is dominated by specialty chemical firms in Japan, Korea, China, and increasingly Europe, making sourcing and formulation IP a competitive differentiator for cell makers.

Battery support materials OEMs and plants

Manufacturer	Product	Location
Arkema	Adhesives	Wauwatosa, WI
Arkema	Binders	Calvert City, KY
Black Diamond Structures	Additives	Austin, TX
Cabot	Additives	Pampa, TX
Daikin America	Additives	Decatur, AL
DuPont	Additives	Wilmington, DE
Halocarbon	Additives	Beech Island, SC
LI-CAP Technologies	Other	Sacramento, CA
Parker LORD	Adhesives	Saegertown, PA
PPG	Other	Pittsburgh, PA
The Chemours Company	Binders	Washington, WV
Volexion	Graphene coating	Evanston, IL

Supply chain & outlook

Electrolyte and separator production is concentrated among specialized chemical and materials companies, many in China, Japan, and South Korea. Risks include dependency on fluorochemicals (for LiPF6), rising demand outpacing separator film capacity, and cost pressures from safety-enhanced designs. Automakers are increasingly partnering with material suppliers to secure allocations and accelerate next-gen R&D (e.g., solid-state). Recycling and recovery of solvents and separator films is limited today but expected to grow in importance.

Rank	Technology	Adoption Drivers	Constraints
1	Liquid Electrolytes + Polyolefin Separators	Mature, cost-effective, scaled supply chain	Safety limitations; thermal runaway risk
2	Ceramic-Coated Separators + Additive-Rich Electrolytes	Improved safety, higher temperature tolerance, faster charging	Higher cost; capacity expansions needed
3	Solid-State Electrolytes & Separators	Game-changing safety and energy density potential	Not yet commercial; manufacturing scale-up challenges

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