Membranes, separators, batteries, and methods

Patent metadata

Field	Value
Publication number	US-2017025658-A1
Application number	US-201615216861-A
Country	US
Kind code	A1
Filing date	Jul 22, 2016
Priority date	Jul 22, 2015
Publication date	Jan 26, 2017
Grant date	—

Abstract

In accordance with at least selected embodiments, novel or improved porous membranes or substrates, separator membranes, separators, composites, electrochemical devices, batteries, methods of making such membranes or substrates, separators, and/or batteries, and/or methods of using such membranes or substrates, separators and/or batteries are disclosed. In accordance with at least certain embodiments, novel or improved microporous membranes, battery separator membranes, separators, energy storage devices, batteries including such separators, methods of making such membranes, separators, and/or batteries, and/or methods of using such membranes, separators and/or batteries are disclosed. In accordance with at least certain selected embodiments, a separator for a battery which has an oxidation protective and binder-free deposition layer which is stable up to 5.2 volts or more, for example, up to 7 volts, in a battery is disclosed. The deposition layer is preferably a thin, very thin or ultra-thin deposition on a polymeric microporous membrane applied via a binder-free and solvent-free deposition method. By employing such an ultra-thin deposition layer, the energy density of a battery may be increased. In accordance with at least particular embodiments, the battery separator membrane described herein is directed to a multi-layer or composite microporous membrane battery separator which may have excellent oxidation resistance and may be stable in a high voltage battery system up to 5.2 volts or more. In accordance with at least other certain selected embodiments, the present invention is directed to a separator for a battery which has a conductive deposition layer which is stable up to at least 5.2 volts or higher in a battery.

First claim

We claim:

1 . A porous membrane or substrate having a thin, very thin or ultra-thin layer of at least one of an inorganic material, organic material, conductive material, semi-conductive material, non-conductive material, reactive material, or mixtures, blends or combinations thereof, such as a metal and/or metal oxide, on at least one side of a polymeric porous or microporous membrane or substrate, wherein said layer is applied using a deposition method or technique such as physical vapor deposition.

2 . The porous membrane or substrate of claim 1 having a layer of a metal and/or metal oxide on at least one side of a polymeric porous or microporous membrane, having a layer applied using a vapor deposition method or technique, having a layer of a metal and/or metal oxide on at least one side of a polymeric porous membrane wherein said layer is applied using a vacuum deposition method, having a layer of metal and/or metal oxide on a polymeric porous membrane wherein said membrane is a component of an electrochemical device, having a layer of metal and/or metal oxide on a polymeric porous membrane wherein said membrane is a component of an electrochemical device that is a capacitor, having a layer of metal and/or metal oxide on a polymeric porous membrane wherein said membrane is a component of an electrochemical device that is a super capacitor or a double layer capacitor, having a layer of metal and/or metal oxide on a polymeric porous or microporous membrane wherein said membrane is a battery separator, having a layer of metal and/or metal oxide on a polymeric porous membrane wherein said membrane is a lithium battery separator, having a layer of metal and/or metal oxide on a polymeric porous membrane wherein said membrane is a primary or secondary battery separator, having a layer of metal and/or metal oxide on at least one side of a polymeric porous membrane wherein said membrane is a lithium primary or secondary battery separator, having a layer of metal and/or metal oxide on a polymeric porous membrane wherein said membrane is a lithium secondary battery separator that is stable against oxidation in a lithium ion battery with a cell voltage up to or equal to 4.9 volts, 5.0 volts, 5.2 volts, 5.5 volts, or higher, wherein cell voltage may be a measure of the potential difference between two electrodes (positive electrode and negative electrode) in an electrochemical cell, having a layer of metal and/or metal oxide on a polymeric porous membrane wherein said membrane is a lithium secondary battery separator that is stable against oxidation in a lithium ion battery with a cell voltage up to or equal to 5.2 volts or more, wherein cell voltage may be a measure of the potential difference between two electrodes (positive electrode and negative electrode) in an electrochemical cell, having a layer of a metal and/or metal oxide on at least one side of a polymeric porous membrane wherein said layer is applied using a deposition method selected from the group including physical vapor deposition, atomic layer deposition, chemical vapor deposition, sputtering, and laser plasma, having a deposition of an inert metal element where non-limiting examples of such inert metal element include gold, platinum, the like, and mixtures thereof, having a deposition of a reactive metal element where non-limiting examples of such reactive metal element include aluminum, nickel, copper, the like, and mixtures thereof, having a deposition of a metal oxide where non-limiting examples of such metal oxide include aluminum oxide (Al 2 O 3 ), boehmite AlO(OH), silicon oxide, titanium oxide and oxides of transition metals and the like or mixtures thereof, having a layer of a metal and/or metal oxide on at least one side of a polymeric porous membrane wherein said layer is applied using a deposition method such as vapor deposition wherein the polymeric porous membrane comprises a polyolefin (where the polyolefin is selected from the group including polypropylene, polyethylene, polymethylpentene, polybutylene, and/or blends, mixtures thereof and their copolymers and combinations thereof) and/or where the membrane or substrate comprises polyvinylidene fluoride (PVdF), polyethylene terephthalate (PET), woven fibers, and/or nonwoven fibers, having a layer of a metal and/or metal oxide on at least one side of a polymeric porous membrane wherein said layer is applied using a deposition method and wherein the membrane or substrate is a monolayer or a multilayer membrane or substrate produced using dry process, a wet process, a particle stretch process, a biaxially oriented polypropylene (BOPP) process, a beta nucleated biaxially oriented polypropylene (BN-BOPP) process, a nonwoven membrane process, or a combination thereof, having a layer of metal and/or metal oxide on at least one side of a polymeric porous membrane wherein said membrane is a lithium primary or secondary battery separator, wherein said deposition layer is applied to the side of the separator facing the cathode, the positive electrode, having a layer of metal and/or metal oxide on both sides of a polymeric porous membrane wherein said membrane is a lithium primary or secondary battery separator, wherein said deposition layer is applied to the side of the separator facing the cathode, the positive electrode, and wherein said deposition layer is applied to the side of the separator facing the anode, the negative electrode, having a layer of metal and/or metal oxide on at least one side of a polymeric porous membrane wherein said membrane is a lithium primary or secondary battery separator, wherein said deposition layer is applied to the side of the separator facing the anode, the negative electrode, having a layer of metal and/or metal oxide on at least one side of a polymeric porous membrane wherein said membrane is a lithium primary or secondary battery separator, wherein said deposition layer is applied to the side of the separator facing the cathode, the positive electrode, and a ceramic coating is applied to the side of the separator facing the anode, the negative electrode, having a deposition layer of metal and/or metal oxide applied on both sides of a polymeric porous membrane wherein said membrane is a lithium primary or secondary battery separator, wherein said deposition layer is applied to the side of the separator facing the cathode, the positive electrode, and said deposition layer is applied to the side of the separator facing the anode, the negative electrode, and a ceramic coating is applied on top of the metal and/or metal oxide deposition layer on the side of the separator facing the anode, the negative electrode, having a deposition layer of metal and/or metal oxide applied on at least one side of a polymeric porous membrane wherein said membrane is a lithium primary or secondary battery separator, wherein said deposition layer is applied to the side of the separator facing the anode, the negative electrode, and a ceramic coating is applied on top of the metal and/or metal oxide deposition layer on the side of the separator facing the anode, the negative electrode, having a deposition layer of metal and/or metal oxide applied on at least one side of a polymeric porous membrane wherein said membrane is a lithium primary or secondary battery separator, wherein said deposition layer is applied to the side of the separator facing the cathode, the positive electrode, and a ceramic coating is applied on top of the metal and/or metal oxide deposition on the side of the separator facing the cathode, the positive electrode, having a deposition layer of metal and/or metal oxide applied on both sides of a polymeric porous membrane wherein said membrane is a lithium primary or secondary battery separator, wherein said deposition layer is applied to the side of the separator facing the cathode, the positive electrode, and wherein said deposition layer is applied to the side o

Assignees

• Celgard Llc

Inventors

• Shi Lie
• Wensley C Glen
• Zhang Zhengming
• Chemelewski Katharine
• Ma Junqing
• Smith Ronnie E
• Cho Kwantai
• Fang Weifeng
• Adams Changqing Wang
• Mccallum Ian
• Nada Jun
• Williams Shante P
• Mangum Jacob S

Classifications

• B05D1/62 Primary

  Plasma-deposition of organic layers (plasma deposition in general C23C14/00, C23C16/00) · CPC title

• H01M10/0525

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

• H01G11/84

  Processes for the manufacture of hybrid or EDL capacitors, or components thereof · CPC title

• B05D1/60

  Deposition of organic layers from vapour phase (vapour phase deposition in general C23C14/00, C23C16/00) · CPC title

• C23C14/24

  Vacuum evaporation · CPC title