An approach was developed to fabricate functionalized separators capable of providing long-term overcharge protection for secondary lithium batteries. Free-standing non-woven fiber membranes consisting of an electroactive polymer and a supporting polymer were prepared by an inexpensive and scalable electrospinning technique. The membranes sustained large shunt current densities despite the presence of an inert polymer component that dilutes the electroactive polymer. A bilayer fiber separator prepared by this method provided a reversible voltage-regulated current shunt for a Li 1.05 Mn 1.95 O 4 /Li cell for more than 1000 135% overcharge cycles at a 2/3 C rate, which is the most stable overcharge protection yet reported. This approach enables better distribution of the electroactive polymer which should reduce the cost of overcharge protection separators. As the battery industry moves toward higher energy density cells and larger packs for vehicular and aviation applications, there is a great need to address the safety hazards associated with cell overcharge/overdischarge. A variety of conditions may be responsible for overcharging in secondary lithium batteries, including charging at normal rates but beyond rated capacity, overvoltage excursions for varying periods, charging at a rate too high for one electrode without exceeding the maximum voltage, and other more complex scenarios. The effectiveness of overcharge protection by the commonly used redox shuttle method 2 is limited by its rate capability, stability, and operating voltage window. Most of the studies performed so far were focused on the LiFePO 4 chemistry which operates at a relatively low 3.45 V vs. Li + /Li. The best result to date is 300 cycles at 100% overcharging of a LiFePO 4 -Li 4/3 Ti 5/3 O 4 cell at C/10 charging rate. 3 We previously developed a novel approach using electroactive polymers for overcharge protection, 4 which has subsequently been investigated by other groups. [5][6][7] When incorporated into a microporous separator membrane, the elecroactive polymer remains insulating during normal cell charge and discharge, but it creates a reversible, resistive internal short upon overcharging. 8 The polymer limits the cell potential and protects the cell components from damage without restricting ion transport in the electrolyte or any significant leakage current. A bilayer configuration, in which a polymer with a higher oxidation potential is placed in contact with the cathode to set the protection voltage and a lower voltage polymer is placed next to the anode to protect the high voltage polymer from degradation at the anode potential, was later introduced to expand the operating voltage window in high-energy cells. 9 The ability of the polymers in providing overcharge protection for LiFePO 4 and LiNi 0.8 Co 0.15 Al 0.05 O 2 cells was clearly demonstrated on the comparison studies of protected and unprotected half cells. Although overcharge protection at both high rates and low temperatures were achieved using the bilayer configuration,...