Coatings, coated separators, batteries, and related methods

Patent metadata

Field	Value
Publication number	US-11879070-B2
Application number	US-202217888954-A
Country	US
Kind code	B2
Filing date	Aug 16, 2022
Priority date	Jul 22, 2016
Publication date	Jan 23, 2024
Grant date	Jan 23, 2024

Abstract

Coating compositions for porous substrates, and/or related methods including methods of manufacture and/or of use thereof are disclosed. Also, coating compositions for porous substrates, where the coating comprises at least a polymeric binder and heat-resistant particles with or without additional additives, materials or components are disclosed. Further, coating compositions for porous substrates 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 coated porous substrates, including battery separators, where the coating composition 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 separator comprising:
a substrate having a polypropylene-polyethylene-polypropylene tri-layer structure;
a coating composition coated on one side of the substrate which comprises:
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 R1, R2, R3, and R4 can be alkyl or aromatic substituents; R5 can be alkyl, aryl, or fused ring;
m can be an integer between 2 and 4, and wherein the ratio of l to n is such that 0≤l:n≤1, and X is an epoxide or an alkyl amine.

2. The separator of claim 1 wherein the polymeric binder comprises at least one selected from the group consisting of a polylactam polymer, polyvinyl alcohol (PVA), Polyacrylic acid (PAA), Polyvinyl acetate (PVAc), carboxymethyl cellulose (CMC), an isobutylene polymer, an acrylic resin, and latex.

3. The separator of claim 2 wherein the polymeric binder comprises a polylactam polymer, which is a homopolymer, co-polymer, block polymer, or block co-polymer derived from a lactam.

4. The separator of claim 3 wherein the homopolymer or co-polymer derived from a lactam is at least one selected from the group consisting of polyvinylpyrrolidone (PVP), polyvinylcaprolactam (PVCap), and polyvinyl-valerolactam.

5. The separator of claim 1 wherein the polymeric binder comprises polyvinyl alcohol (PVA), polyacrylic acid (PAA), polyvinyl acetate (PVAc), carboxymethyl cellulose (CMC), an isobutylene polymer, acrylic resin, and/or latex.

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

7. The separator of claim 1 wherein the adhesion agent comprises a thermoplastic fluoropolymer.

8. The separator 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.

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

10. The separator of claim 1 wherein the coating layer further comprises another different coating layer formed thereon.

11. A secondary lithium ion battery comprising the separator of claim 1 .

12. A composite comprising the separator of claim 1 in direct contact with an electrode for a secondary lithium ion battery.

13. A vehicle or device comprising the battery of claim 11 .

14. 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.

15. The coating composition of claim 14 wherein the ratio of heat-resistant particles to binder in the coating composition is 50:50 to 99:1.

16. The coating composition of claim 14 wherein 0.01 to 99.99% of the surface area of at least one of the heat-resistant particles is coated by the binder.

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

18. The coating composition of claim 17 wherein the cross-linker is an epoxy cross-linker comprising multiple reactive epoxy groups.

19. The coating composition of claim 17 wherein the cross-linker is an acrylate cross-linker comprises multiple reactive acrylate groups.

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

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

22. 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.

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

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

25. 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.

26. A secondary lithium ion battery comprising the separator of claim 24 .

27. A composite comprising the separator of claim 25 in direct contact with an electrode for a secondary lithium ion battery.

28. A vehicle or device comprising the secondary lithium ion battery of claim 26 .

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

• C09D5/18 Primary

  Fireproof paints {including high temperature resistant paints} · CPC title

• C09D7/20

  Diluents or solvents · CPC title

• C09D129/04

  Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids · CPC title

• C09D133/04

  Homopolymers or copolymers of esters {(C09D143/04 takes precedence)} · CPC title