The single-layered microporous polyethylene separator is prepared by dry process and has been stretched in uni-axial direction to two different ratios namely 180 and 300 % in order to create high-performance and cost-effective separator for practical application in lithium-ion batteries. In this study, the structures of the microporous polyethylene separator prepared by dry process and uni-axially stretched to two different ratios of 180 and 300 % were characterized. The physical structure of the stretched separator is characterized by key factors such as thickness, mean pore size, porosity, Gurley value, ionic resistivity, MacMullin number and tortuosity. The thermal behavior of the stretched separator is explained by using differential scanning calorimeter (DSC). DSC explains the melting and shutdown behavior of the separator. Electrochemical property is studied by linear sweep voltammetry, electrochemical impedance spectroscopy (EIS) and cyclic performance. EIS is performed to explain, in elaborate, the resistance of separator and the specific discharge capacity is observed using the cyclic performance. Three hundred percent stretched separator is observed to have comparatively less resistance and higher discharge capacity than the 180 % stretched separator.
