Microlayer membranes, battery separators, batteries, and related methods

Patent metadata

Field	Value
Publication number	US-11969929-B2
Application number	US-201917054190-A
Country	US
Kind code	B2
Filing date	May 10, 2019
Priority date	May 10, 2018
Publication date	Apr 30, 2024
Grant date	Apr 30, 2024

Abstract

Described herein is a multilayer microporous film or membrane that may exhibit improved properties, including improved dielectric break down and strength, compared to prior monolayer or tri-layer microporous membranes of the same thickness. The preferred multilayer microporous membrane comprises microlayers and one or more lamination interfaces or barriers. Also disclosed is a battery separator or battery comprising one or more of the multilayer microporous films or membranes. The inventive battery and battery separator is preferably safer and more robust than batteries and battery separators using prior monolayer and tri-layer microporous membranes. Also, described herein is a method for making the multilayer microporous separators, membranes or films described herein.

First claim

The invention claimed is:

1. A multilayer microporous membrane or film having or exhibiting at least one of following:
(a) having at least one additive in at least one layer of the multilayer microporous membrane or film;
(b) having or exhibiting increased or improved compressibility compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film;
(c) having or exhibiting increased or improved elongation at break (TD) compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film:
(d) having or exhibiting reduced high temperature shrinkage at 150° C. compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film;
(e) having or exhibiting reduced high temperature shrinkage at 120° C. compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film;
(f) having at least one layer that comprises a polymer blend; and
(g) having a non-woven or woven attached to one or both sides of the multilayer microporous membrane or film, wherein the membrane or film has or exhibits increased or improved elasticity at or above 150° C. compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film, and optionally wherein:
tan(delta) of the membrane or film, when measured according to dynamic mechanical analysis, is greater than −0.6 at 150° C.;
tan(delta) of the membrane or film, when measured according to dynamic mechanical analysis, is between −1.0 and −0.6 at a temperature between 175° C. and 200° C.;
tan(delta) of the membrane or film, when measured according to dynamic mechanical analysis, is between −0.9 and −0.6 at a temperature between 175° C. and 200° C.;
tan(delta) of the membrane or film, when measured according to dynamic mechanical analysis is between −0.8 and −0.6 at a temperature between 175° C. and 200° C.;
tan(delta) of the membrane or film, when measured according to dynamic mechanical analysis is between −0.7 and −0.6 at a temperature between 175° C. and 200° C.;
tan(delta) of the membrane or film, when measured according to dynamic mechanical analysis, is above −1.2 at temperatures at or above 200° C.;
tan(delta) of the membrane or film, when measured according to dynamic mechanical analysis is above −1.0 at temperatures at or above 200° C.; or
tan(delta) of the membrane or film, when measured according to dynamic mechanical analysis is above is above −0.8 at temperatures at or above 200° C.

2. A multilayer microporous membrane or film having or exhibiting at least one of following:
(a) having at least one additive in at least one layer of the multilayer microporous membrane or film;
(b) having or exhibiting increased or improved compressibility compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film;
(c) having or exhibiting increased or improved elongation at break (TD) compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film:
(d) having or exhibiting reduced high temperature shrinkage at 150° C. compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film;
(e) having or exhibiting reduced high temperature shrinkage at 120° C. compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film;
(f) having at least one layer that comprises a polymer blend; and
(g) having a non-woven or woven attached to one or both sides of the multilayer microporous membrane or film, wherein the membrane or film has or exhibits increased or improved compressibility compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film.

3. A multilayer microporous membrane or film having or exhibiting at least one of following:
(a) having at least one additive in at least one layer of the multilayer microporous membrane or film;
(b) having or exhibiting increased or improved compressibility compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film;
(c) having or exhibiting increased or improved elongation at break (TD) compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film:
(d) having or exhibiting reduced high temperature shrinkage at 150° C. compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film;
(e) having or exhibiting reduced high temperature shrinkage at 120° C. compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film;
(f) having at least one layer that comprises a polymer blend; and
(g) having a non-woven or woven attached to one or both sides of the multilayer microporous membrane or film, wherein the membrane or film has or exhibits increased or improved elongation at break (TD) compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film, wherein:
the elongation at break (TD) may be more than 30% higher, 35% higher, 40% higher, 41% higher, 42% higher, 43% higher, 44% higher, or 45% higher, compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film.

4. A multilayer microporous membrane or film having or exhibiting at least one of following:
(a) having at least one additive in at least one layer of the multilayer microporous membrane or film;
(b) having or exhibiting increased or improved compressibility compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film;
(c) having or exhibiting increased or improved elongation at break (TD) compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film:
(d) having or exhibiting reduced high temperature shrinkage at 150° C. compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film;
(e) having or exhibiting reduced high temperature shrinkage at 120° C. compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film;
(f) having at least one layer that comprises a polymer blend; and
(g) having a non-woven or woven attached to one or both sides of the multilayer microporous membrane or film, wherein the membrane or film has or exhibits reduced high temperature shrinkage at 120° C. compared to a tri-layer microporous membrane having the same thickness, Gurley, porosity, and/or resin make-up as the multilayer microporous membrane or film, wherein:
the membrane or film may have a high temperature shrinkage at 120° C. that is 30 to 75% lower, 35 to 70% lower, 35 to 65% l

Assignees

• Celgard Llc

Inventors

• Xiao Kang Karen
• Reinartz Stefan
• Kondo Takahiko
• Ikebata Hisaki
• Penegar Eric J
• Nark Robert
• Adams Changqing Wang
• Okada Masaaki
• Stepp Brian R
• White Eric Robert
• Donn Allen M
• Chemelewski Katharine

Classifications

• H01M50/403

  Manufacturing processes of separators, membranes or diaphragms · CPC title

• H01M50/414

  Synthetic resins, e.g. thermoplastics or thermosetting resins · CPC title

• H01M50/491 Primary

  Porosity · CPC title

• B29C48/21 Primary

  the layers being joined at their surfaces · CPC title

• B01D67/0079

  Manufacture of membranes comprising organic and inorganic components · CPC title