Coatings, coated separators, batteries, and related methods

Patent metadata

Field	Value
Publication number	US-11437684-B2
Application number	US-201716318405-A
Country	US
Kind code	B2
Filing date	Jul 21, 2017
Priority date	Jul 22, 2016
Publication date	Sep 6, 2022
Grant date	Sep 6, 2022

Abstract

New and/or improved coatings for porous substrates, including battery separators or separator membranes, and/or coated porous substrates, including coated battery separators, and/or batteries or cells including such coatings or coated separators, and/or related methods including methods of manufacture and/or of use thereof are disclosed. Also, new or improved coatings for porous substrates, including battery separators, which comprise at least a polymeric binder and heat-resistant particles with or without additional additives, materials or components, and/or to new or improved coated porous substrates, including battery separators, where the coating comprises at least a polymeric binder and heat-resistant particles with or without additional additives, materials or components are disclosed. Further, new or improved coatings for porous substrates, including battery separators, and new and/or improved coated porous substrates, including battery separators, new or improved coatings for porous substrates, including battery separators, which comprise at least (i) a polymeric binder, (ii) heat-resistant particles, and (iii) at least one component selected from the group consisting of a cross-linker, a low-temperature shutdown agent, an adhesion agent, and a thickener, and new and/or improved coated porous substrates, including battery separators, where the coating comprises at least (i) a polymeric binder, (ii) heat-resistant particles, and (iii) at least one component selected from the group consisting of a cross-linker, a low-temperature shutdown agent, an adhesion agent, a thickener, a friction-reducing agent, a high-temperature shutdown agent are disclosed.

First claim

The invention claimed is:

1. A coating composition comprising:
a polymeric binder comprises water as the solvent, an aqueous solvent, or a non-aqueous solvent;
heat-resistant particles; and
at least one component selected from the group consisting of a cross-linker, a low-temperature shutdown agent, an adhesion agent, a thickener, a friction reducing agent, and a high-temperature shutdown agent;
wherein the polymeric binder comprises a polylactam of Formula (1):

wherein R 1 , R 2 , R 3 , and R 4 can be alkyl or aromatic substituents and R 5 can be alkyl, aryl, or fused ring; and
wherein the polylactam can be a homopolymer or a co-polymer where co-polymeric group X can be derived from vinyl, a substituted or un-substituted alkyl vinyl, vinyl alcohol, vinyl acetate, acrylic acid, alkyl acrylate, acrylonitrile, maleic anhydride, maleic imide, styrene, polyvinylpyrrolidone (PVP), polyvinylvalerolactam, polyvinylcaprolactam (PVCap), polyamide, or polyimide;
wherein m can be an integer between 1 and 10,
and wherein the ratio of 1 to n is such that 0≤1:n≤10.

2. A coating composition comprising:
a polymeric binder comprises water as the solvent, an aqueous solvent, or a non-aqueous solvent;
heat-resistant particles; and
at least one component selected from the group consisting of a cross-linker, a low-temperature shutdown agent, an adhesion agent, a thickener, a friction reducing agent, and a high-temperature shutdown agent;
wherein the polymeric coating comprises a polylactam according to Formula (2) and a catalyst:

wherein R 1 , R 2 , R 3 , and R 4 can be alkyl or aromatic substituents;
R 5 can be alkyl, aryl, or fused ring;
m can be an integer between 1 and 10,
and wherein the ratio of 1 to n is such that 0≤1:n≤10,
and X is an epoxide or an alkyl amine.

3. The coating composition of claim 2 wherein X is an epoxide and the catalyst comprises an alkyl amine or epoxide.

4. The coating composition of claim 1 wherein the heat-resistant particles comprise an organic material or a mixture of an organic material and an inorganic material, and the organic material is at least one selected from the group consisting of: a polyimide resin, a melamine resin, a phenol resin, a polymethyl methacrylate (PMMA) resin, a polystyrene resin, a polydivinylbenzene (PDVB) resin, carbon black, and graphite.

5. The coating composition of claim 4 wherein the ratio of heat-resistant particles to binder in the coating composition is 50:50 to 99:1.

6. The coating composition of claim 4 wherein 0.01 to 99.99% of the surface area of at least one of the heat-resistant particles is coated by the binder.

7. The coating composition of claim 1 wherein the cross-linker comprising multiple reactive groups.

8. The coating composition of claim 7 wherein the cross-linker is an epoxy cross-linker comprising multiple reactive epoxy groups.

9. The coating composition of claim 7 wherein the cross-linker is an acrylate cross-linker comprises multiple reactive acrylate groups.

10. The coating composition of claim 1 wherein the low-temperature shutdown agent comprises at least one of polyethylene (PE) and polyvinyl pyrrolidone (PVP).

11. The coating composition of claim 1 wherein the adhesion agent comprises a thermoplastic fluoropolymer.

12. The coating composition of claim 1 wherein the friction reducing agent is at least one selected from a metallic stearate, a siloxane, a silicone resin, a fluororesin, a wax, and an aliphatic amide.

13. The coating composition of claim 1 wherein the high-temperature shutdown agent has a melting point of 140 to 220° C.

14. The coating composition of claim 1 wherein the high-temperature shutdown agent is selected from polyvinylpyrrolidone (PVP) or polyvinylidene difluoride (PVDF).

15. A separator comprising a porous substrate and a coating layer formed on at least one surface of the porous substrate, wherein the coating layer comprises a coating composition of claim 1 and the coating layer further comprises another different coating layer formed thereon.

16. A secondary lithium ion battery comprising the separator of claim 15 .

17. A composite comprising the separator of claim 15 in direct contact with an electrode for a secondary lithium ion battery.

18. A vehicle or device comprising the secondary lithium ion battery of claim 16 .

19. The coating composition of claim 2 wherein the heat-resistant particles comprise an organic material or a mixture of an organic material and an inorganic material, and the organic material is at least one selected from the group consisting of: a polyimide resin, a melamine resin, a phenol resin, a polymethyl methacrylate (PMMA) resin, a polystyrene resin, a polydivinylbenzene (PDVB) resin, carbon black, and graphite.

20. The coating composition of claim 19 wherein the ratio of heat-resistant particles to binder in the coating composition is 50:50 to 99:1.

21. The coating composition of claim 19 wherein 0.01 to 99.99% of the surface area of at least one of the heat-resistant particles is coated by the binder.

22. The coating composition of claim 2 wherein the cross-linker comprising multiple reactive groups.

23. The coating composition of claim 22 wherein the cross-linker is an epoxy cross-linker comprising multiple reactive epoxy groups.

24. The coating composition of claim 22 wherein the cross-linker is an acrylate cross-linker comprises multiple reactive acrylate groups.

25. The coating composition of claim 2 wherein the low-temperature shutdown agent comprises at least one of polyethylene (PE) and polyvinyl pyrrolidone (PVP).

26. The coating composition of claim 2 wherein the adhesion agent comprises a thermoplastic fluoropolymer.

27. The coating composition of claim 2 wherein the friction reducing agent is at least one selected from a metallic stearate, a siloxane, a silicone resin, a fluororesin, a wax, and an aliphatic amide.

28. The coating composition of claim 2 wherein the high-temperature shutdown agent has a melting point of 140 to 220° C.

29. The coating composition of claim 2 wherein the high-temperature shutdown agent is selected from polyvinylpyrrolidone (PVP) or polyvinylidene difluoride (PVDF).

30. A separator comprising a porous substrate and a coating layer formed on at least one surface of the porous substrate, wherein the coating layer comprises a coating composition of claim 2 and the coating layer further comprises another different coating layer formed thereon.

31. A secondary lithium ion battery comprising the separator of claim 30 .

32. A composite comprising the separator of claim 30 in direct contact with an electrode for a secondary lithium ion battery.

33. A vehicle or device comprising the secondary lithium ion battery of claim 31 .

Assignees

• Celgard Llc

Inventors

• Lane Michael B
• Jeon Insik
• Kruger Edward
• Yu Xiang
• Smith Ronnie E
• Reinartz Stefan
• Ma Junqing

Classifications

• C09D7/65 Primary

  macromolecular (C09D7/41-C09D7/48 take precedence) · CPC title

• H01M50/461

  with adhesive layers between electrodes and separators · CPC title

• H01M50/457

  comprising three or more layers · CPC title

• H01M50/451

  comprising layers of only organic material and layers containing inorganic material · CPC title

• H01M50/426

  Fluorocarbon polymers · CPC title