Separator coating materials for rechargeable batteries

Patent metadata

Field	Value
Publication number	US-12548851-B2
Application number	US-202217856003-A
Country	US
Kind code	B2
Filing date	Jul 1, 2022
Priority date	Jul 1, 2022
Publication date	Feb 10, 2026
Grant date	Feb 10, 2026

Abstract

A coated separator for a rechargeable battery includes a porous polymer sheet comprising a surface; and a coating disposed on the surface, the coating comprising a metal oxyhydroxide; wherein: the coating includes a greater HF score when normalized to that of AlO(OH) at 100%; a greater PF5− score when normalized to that of AlO(OH) at 100%; or a greater LiOH score when normalized to that of AlO(OH) at 100%; or a combination of any two or more thereof.

First claim

What is claimed is:

1 . A coated separator comprising:
a porous polymer sheet comprising a surface; a coating disposed on the surface, the coating comprising a metal oxyhydroxide comprising ScO(OH) or VO(OH) or a mixture thereof;
the coating comprises:
an HF score greater than that of AlO(OH) where the HF score of AlO(OH) is normalized at 100%;
a PF 5 − score greater than when normalized to that of AlO(OH) where the PF 5 − score of AlO(OH) is normalized at 100%; or
a LiOH score greater than that of AlO(OH) where the LiOH score of AlO(OH) is normalized at 100%; or
a combination of any two or more thereof.

2 . The coated separator of claim 1 , wherein the metal oxyhydroxide comprises ScO(OH).

3 . The coated separator of claim 1 , wherein the coating further comprises SiO 2 , Al 2 O 3 , or AlO(OH), or a mixture of any two or more thereof.

4 . The coated separator of claim 1 , wherein the coating comprises:
a first layer comprising SiO 2 , Al 2 O 3 , or AlO(OH), or a mixture of any two or more thereof; and a second layer comprising the ScO(OH) or VO(OH), or a mixture thereof.

5 . The coated separator of claim 1 , wherein the porous polymer sheet comprises cellulose, polyethylene, or polypropylene, or a combination of any two or more thereof.

6 . The coated separator of claim 1 , wherein:
the surface is a first surface of the porous polymer sheet, the porous polymer sheet comprising the first surface and a second surface opposite the first surface; and the coated separator further comprises a second coating disposed on the second surface of the porous polymer sheet, the second coating comprising a metal oxyhydroxide.

7 . The coated separator of claim 1 , wherein:
the surface is a first surface of the porous polymer sheet, the porous polymer sheet comprising the first surface and a second surface opposite the first surface; and the porous polymer sheet comprises a thickness between the first surface and the second surface of about 3 μm to about 40 μm.

8 . The coated separator of claim 1 , wherein the porous polymer sheet comprises a porosity as determined by mercury porosimetry of about 30% to about 80%.

9 . The coated separator of claim 1 , wherein the porous polymer sheet comprises pore sizes as determined by mercury porosimetry of about 20 nm to about 80 nm.

10 . The coated separator of claim 1 , wherein the porous polymer sheet comprises a machine direction tensile strength of about 1,000 kgf/cm 2 to about 2,500 kgf/cm 2 .

11 . The coated separator of claim 1 , wherein the coating comprises an average thickness of about 0.1 μm to about 15 μm.

12 . The coated separator of claim 1 , wherein the coating is a ceramic coating.

13 . A lithium ion battery comprising:
a cathode comprising a cathode active material; and a coated separator; wherein:
the coated separator comprises:
a porous polymer sheet comprising a surface;
a coating disposed on the surface, the coating comprising a metal oxyhydroxide comprising ScO(OH) or VO(OH) or a mixture thereof; and

the coating comprises:
an HF score greater than that of AlO(OH) where the HF score of AlO(OH) is normalized at 100%;
a PF 5 − score greater than when normalized to that of AlO(OH) where the PF 5 − score of AlO(OH) is normalized at 100%; or
a LiOH score greater than when normalized to that of AlO(OH) where the LiOH score of AlO(OH) is normalized at 100%; or
a combination of any two or more thereof.

14 . The lithium ion battery of claim 13 , wherein the metal oxyhydroxide comprises the ScO(OH), VO(OH).

15 . The lithium ion battery of claim 13 , wherein the cathode comprises LiFePO 4 , LiMn 1-x FePO 4 , LiM 1 O 2 , or Li 1+x M 2 1-x O 2 , or a mixture of any two or more thereof, where independently at each occurrence 0≤x≤1 and M 1 and M 2 are each independently Ni, Co, Mn, or Al.

16 . The lithium ion battery of claim 13 , wherein the coating is between the porous polymer sheet and the cathode.

17 . The lithium ion battery of claim 13 , wherein the metal oxyhydroxide comprises VO(OH).

18 . A process of manufacturing a coated separator for a lithium ion battery, the process comprising:
mixing a metal oxyhydroxide comprising ScO(OH) or VO(OH) or a mixture thereof and optionally a binder in a solvent to form a slurry; coating the slurry onto a surface of a porous polymer sheet; and removing the solvent to provide the coated separator, the coated separator comprising a coating disposed on the surface of the porous polymer sheet; wherein:
the coating comprises:
an HF score greater than that of AlO(OH) where the HF score of AlO(OH) is normalized at 100%;
a PF 5 − score greater than when normalized to that of AlO(OH) where the PF 5 − score of AlO(OH) is normalized at 100%; or
a LiOH score greater than that of AlO(OH) where the LiOH score of AlO(OH) is normalized at 100%; or
a combination of any two or more thereof.

19 . The process of claim 18 , wherein the metal oxyhydroxide comprises VO(OH).

20 . The process of claim 18 , wherein the metal oxyhydroxide comprises ScO(OH).

Assignees

• Rivian Ip Holdings Llc

Inventors

• Kim Soo
• Jeong Sookyung
• Kim Tae Kyoung
• Park Ki Tae

Classifications

• H01M50/434

  Ceramics · CPC title

• H01M10/0525 Primary

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• H01M50/494

  Tensile strength · CPC title

• H01M50/491

  Porosity · CPC title

• H01M50/403

  Manufacturing processes of separators, membranes or diaphragms · CPC title