Separators, batteries, systems, vehicles, and related methods

Patent metadata

Field	Value
Publication number	US-10944087-B2
Application number	US-201716070817-A
Country	US
Kind code	B2
Filing date	Jan 27, 2017
Priority date	Jan 29, 2016
Publication date	Mar 9, 2021
Grant date	Mar 9, 2021

Abstract

Improved battery separators, base films or membranes and/or a method of making or using such separators, base films or membranes are provided. The preferred inventive separators, base films or membranes are made by a dry-stretch process and have improved strength, high porosity, high charge capacity and high porosity to provide excellent charge rate and/or charge capacity performance in a rechargeable battery.

First claim

We claim:

1. A membrane comprising:
a microporous polymer film made by a dry-stretch process and having substantially round shaped pores, and a ratio of machine direction tensile strength to transverse direction tensile strength in the range of 0.5 to 6.0, and porosity in the range of 50% to 80%, a mean flow pore diameter from about 0.050 to about 0.50 microns, and a JIS Gurley of from about 20 to about 70 seconds;
wherein the microporous polymer film provides a battery with at least 3 C charge and/or discharge performance.

2. The membrane according to claim 1 wherein the polymer film comprising at least one of a semi-crystalline polymer and a semi-crystalline polymer having a crystallinity in the range of 20-80%.

3. The membrane according to claim 1 wherein said polymer film comprises at least one polymer selected from the group consisting of polyolefins, fluorocarbons, polyamides, polyesters, polyacetals (or polyoxymethylenes), polysulfides, polyvinyl alcohols, co-polymers thereof, and combinations thereof.

4. The membrane according to claim 1 wherein an average pore size of said microporous polymer film being in the range of 0.09 to 0.99 microns.

5. The membrane according to claim 1 wherein said microporous polymer film having a porosity in the range of 60-80%.

6. The membrane according to claim 1 wherein said transverse tensile strength being ≥500 Kg/cm 2 .

7. The membrane according to claim 1 having a thickness in the range of 10-25 microns, a porosity in the range of 60-80%, a transverse direction (TD) tensile strength in the range of 500-700 Kg/cm 2 , a machine direction (MD) tensile strength in the range of 700-1000 Kg/cm2, and a MD/TD tensile strength ratio in the range of 1.4-1.6.

8. The membrane of claim 1 wherein the microporous polymer film provides a battery with a discharge rate of at least 5 C.

9. The membrane of claim 1 wherein the microporous polymer film provides a battery with a discharge rate of at least 10 C.

10. A battery separator comprising the membrane of claim 1 .

11. The battery separator of claim 10 wherein the membrane being at least one ply of a multi-ply membrane.

12. The battery separator of claim 11 wherein the plies of the multi-ply membrane are laminated to one another.

13. The battery separator of claim 10 wherein the membrane being all plies of a multi-ply membrane.

14. The battery separator of claim 10 wherein the plies of the multi-ply membrane being made of the same materials.

15. The battery separator of claim 10 wherein the plies of the multi-ply membrane being made of differing materials.

16. A battery comprising the battery separator of claim 11 .

17. A multi-layered membrane structure comprising the membrane of claim 1 .

18. The multi-layered membrane structure of claim 17 wherein the plies of the multi-ply membrane are co-extruded.

19. The multi-layered membrane structure of claim 18 wherein the plies of the multi-ply membrane being made of the same materials.

20. The multi-layered membrane structure of claim 18 wherein the plies of the multi-ply membrane being made of differing materials.

21. A device having a membrane, the membrane being the membrane according to claim 1 , wherein the device being: a battery, cell, battery pack, system, electronic device, vehicle, or fuel cell.

Assignees

• Celgard Llc

Inventors

• Zhang Xiaomin
• Rumierz Gerald P
• Humiston Karl F
• Haire Charles E
• Fields Tyrone S
• Braswell Michael A
• Proctor Ronald A
• Smith Ronnie E

Classifications

• H01M50/449

  having a layered structure · CPC title

• H01M50/463

  Separators, membranes or diaphragms characterised by their shape · CPC title

• H01M50/411

  Organic material · CPC title

• B29C65/00 Primary

  Joining {or sealing} of preformed parts {, e.g. welding of plastics materials}; Apparatus therefor {(general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326)} · CPC title

• H01M50/457

  comprising three or more layers · CPC title