Separator, method of manufacturing separator, and electrochemical device including separator

Patent metadata

Field	Value
Publication number	US-12438234-B2
Application number	US-202418663073-A
Country	US
Kind code	B2
Filing date	May 14, 2024
Priority date	Jun 9, 2022
Publication date	Oct 7, 2025
Grant date	Oct 7, 2025

Abstract

A separator, a method of manufacturing the separator, and an electrochemical device including the separator. The separator includes: a porous substrate; and an inorganic particle layer formed on at least one surface of the porous substrate, wherein a release rate of the inorganic particle layer is 70% or more when measured by immersing the separator in a water tank at room temperature and then subjecting the separator to sonication under conditions of a frequency of 40 kHz, an output of 1,000 W, and an application time of 60 seconds.

First claim

What is claimed is:

1. A separator comprising:
a porous substrate; and
an inorganic particle layer formed on at least one surface of the porous substrate and including inorganic particles and a hydrolytic condensate of a silane compound,
wherein a release rate of the inorganic particle layer represented by the following Formula (1) is 70% or more when measured by immersing the separator in a water tank at room temperature and then subjecting the separator to sonication under conditions of a frequency of 40 kHz, an output of 1,000 W, and an application time of 60 seconds:

(

w
i

-

w
f

)

/

w
c

*
100

(
1
)

wherein
w i is a weight of the separator before the sonication,
w f is a weight of the separator after the sonication, and
w c is a weight of the inorganic particle layer before the sonication.

2. The separator of claim 1 , wherein the release rate of the inorganic particle layer is 80% or more.

3. The separator of claim 1 , wherein the inorganic particle layer has a (D80−D20)/D50 value of 0.01 to 2.0 in a particle size distribution of inorganic particles.

4. The separator of claim 1 , wherein when specimens each having a thickness of 5 to 50 μm, a width of 5 mm, and a length of 10 mm in each of a machine direction (MD) and a transverse direction (TD) serving as length directions are prepared from the separator, and each specimen is mounted on a chamber of a thermomechanical analyzer (TMA) by hooking both ends of each specimen to a metal jig and pulled downward with a force of 0.008 N while heating at 5° C. per minute, the specimens have a heat resistance in which the specimens are broken at a temperature of 180° C. or higher.

5. The separator of claim 1 , wherein a heat shrinkage rate in each of MD and TD is 3% or less when measured after the separator is allowed to stand at 150° C. for 60 minutes.

6. The separator of claim 1 ,
wherein the hydrolytic condensate of the silane compound is a hydrolytic condensate produced under a condition in which the silane compound is hydrolyzed and is condensation-suppressed in a weakly acidic atmosphere.

7. The separator of claim 6 , wherein the silane compound is a compound represented by the following Chemical Formula 1:
A a Si(OR) b   Chemical Formula 1

wherein A is hydrogen, a polar functional group, or a C1-C10 alkyl group having a polar functional group, R is independent of hydrogen or a C1-C5 alkyl group, a is 0 to 2, b is 2 to 4, and a+b is 4, and
wherein the polar functional group includes one or two or more of an amino group, an epoxy group, a carboxyl group, a hydroxyl group, an amide group, a thiol group, a ketone group, an ester group, and an aldehyde group.

8. The separator of claim 1 , wherein the porous substrate has a surface including a polar functional group.

9. An electrochemical device comprising the separator of claim 1 .

Assignees

• Sk Innovation Co Ltd
• Sk Ie Tech Co Ltd

Inventors

• Kim Yun Bong
• Cho Kyu Young
• Kwon Tae Wook
• Bae Heung Taek

Classifications

• H01M10/052

  Li-accumulators · CPC title

• H01M50/449

  having a layered structure · CPC title

• H01M50/403 Primary

  Manufacturing processes of separators, membranes or diaphragms · CPC title

• H01M50/446

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

• H01M50/443

  Particulate material · CPC title