Rechargeable battery separators containing controlled pores were fabricated via the thermally-induced phase separation (TIPS) process. Based on the idea that pores could be manipulated by controlling the liquid-liquid phase separation temperature in the TIPS process, phase boundaries of the polymer-diluent systems were controlled by using diluent mixtures. Phase behaviors of the polymer/diluent/diluent ternary blends consisting of polyethylene (PE) as polymer, and soybean oil (SBO) and dioctyl phthalate (DOP) as diluents were explored. PE/SBO and PE/DOP binary blends, and PE/SOB/DOP ternary blends exhibited typical upper critical solution temperature (UCST) type phase behaviors, and the phase separation temperatures of the PE/SBO blends were higher than those of the PE/DOP blends. When the mixing ratio of the polymer and diluent-mixture was fixed, the phase separation temperature of the PE/SBO/DOP blend initially increased with increasing SBO content in the diluent-mixture passing through a maximum centered at about 80 wt% SBO and decreased beyond this point. Furthermore, the phase separation temperature of the PE/diluent-mixture blend was always higher than that of the PE/SBO blend when the diluent-mixture contained more than or equal to 50 wt% SBO. To understand the observed phase behavior of the blends, thermodynamic analyses based on the lattice-fluid theory were performed. Larger pore membranes were fabricated from the blend when higher phase separation temperatures of the blend were exhibited. (C) 2007 Elsevier B.V. All rights reserved.