Coated separators, lithium batteries, and related methods

Patent metadata

Field	Value
Publication number	US-11949124-B2
Application number	US-201916964000-A
Country	US
Kind code	B2
Filing date	Jan 4, 2019
Priority date	Jan 22, 2018
Publication date	Apr 2, 2024
Grant date	Apr 2, 2024

Abstract

New and/or improved coatings, layers or treatments for porous substrates, including battery separators or separator membranes, and/or coated or treated 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 matrix material or a polymeric binder, and heat-resistant particles with additional additives, materials or components, and/or to new or improved coated or treated porous substrates, including battery separators, where the coating comprises at least a matrix material or a polymeric binder, and heat-resistant particles with 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 matrix material or 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 matrix material or 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, and a high-temperature shutdown agent are disclosed.

First claim

The invention claimed is:

1. A separator for a high energy rechargeable lithium battery comprises:
at least one ceramic composite layer, said layer being formed from a coating composition which includes from 0.5 to 95 wt % of a matrix material or a polymeric binder, from 5 to 95 wt % of heat-resistant particles, and from 5,000 ppm to 50,000 ppm of a cross-linker, wherein the cross-linker comprises multiple reactive epoxy groups, said ceramic composite layer being adapted to at least block dendrite growth and to prevent electronic shorting;
and at least one polyolefinic microporous layer being adapted to block ionic flow between an anode and a cathode at shutdown temperature;
wherein the polymeric binder comprises a polylactam of Formula (1):
wherein R 1 , R 2 , R 3 , and R 4 are alkyl or aromatic substituents and R 5 is
alkyl, aryl, or fused ring; and

wherein the polylactam is a homopolymer or a co-polymer where co-polymeric group X is 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 l to n is such that 0≤l:n≤10.

2. The separator according to claim 1 wherein said coating composition comprises between 20% to 95% by weight of said heat-resistant particles and between 5% to 80% by weight of said matrix material or polymeric binder.

3. The separator according to claim 1 wherein said heat-resistant particles are selected from the group consisting of SiO 2 , Al 2 O 3 , CaCO 3 , TiO 2 , SiS 2 , SiPO 4 , and mixtures thereof.

4. The separator according to claim 1 wherein said polymeric binder comprises water as a solvent, an aqueous solvent, or a nonaqueous solvent.

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

6. The separator according to 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, and a polydivinylbenzene (PDVB) resin.

7. The separator according to claim 1 wherein the ratio of heat-resistant particles to binder in the coating composition is 50:50 to 99:1 or wherein 0.01 to 99.99% of the surface area of at least one of the heat-resistant particles is coated by the binder.

8. The separator according to claim 1 wherein the ceramic composite layer further comprises another different coating layer formed thereon.

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

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

11. A vehicle or device comprising the separator of claim 1 .

12. A high energy rechargeable lithium battery comprising:
an anode containing lithium metal or lithium-alloy or a mixtures of lithium metal and/or lithium alloy and another material;
a cathode;
a separator according to claim 1 disposed between said anode and said cathode; and an electrolyte in ionic communication with said anode and said cathode via said separator.

Assignees

• Celgard Llc

Inventors

• Zhang Zhengming
• Lane Michael B
• Jeon Insik
• Kruger Edward
• Yu Xiang
• Smith Ronnie E
• Reinartz Stefan
• Ma Junqing
• Alexander Daniel R

Classifications

• H01M50/446 Primary

  Composite material consisting of a mixture of organic and inorganic materials · CPC title

• H01M4/382

  Lithium (H01M4/405 takes precedence) · CPC title

• H01M4/405

  Alloys based on lithium · CPC title

• H01M10/052 Primary

  Li-accumulators · CPC title

• H01M50/403

  Manufacturing processes of separators, membranes or diaphragms · CPC title