Coatings, coated separators, batteries, and related methods

Patent metadata

Field	Value
Publication number	US-2020335759-A1
Application number	US-201716318405-A
Country	US
Kind code	A1
Filing date	Jul 21, 2017
Priority date	Jul 22, 2016
Publication date	Oct 22, 2020
Grant date	—

Abstract

New and/or improved coatings for porous substrates, including battery separators or separator membranes, and/or coated 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 polymeric binder and heat-resistant particles with or without additional additives, materials or components, and/or to new or improved coated porous substrates, including battery separators, where the coating comprises at least a polymeric binder and heat-resistant particles with or without 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 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 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, a high-temperature shutdown agent are disclosed.

First claim

1 . A coating composition, comprising:
a polymeric binder, which optionally comprises water as the solvent, an aqueous solvent, or a non-aqueous solvent; heat-resistant particles; 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; and optionally, at least one selected from the group consisting of surfactants, antioxidants, fillers, colorants, stabilizing agents, de-foaming agents, de-bubbling agents, thickeners, emulsifiers, pH buffers, emulsification agents, surfactants, anti-settling agents, levelers, rheology modifiers, and wetting agents.

2 . The coating composition of claim 1 , wherein the polymeric binder comprises at least one selected from the group consisting of a polylactam polymer, polyvinyl alcohol (PVA), Polyacrylic acid (PAA), Polyvinyl acetate (PVAc), carboxymethyl cellulose (CMC), an isobutylene polymer, an acrylic resin, and latex.

3 . The coating composition of claim 2 , wherein the polymeric binder comprises a polylactam polymer, which is a homopolymer, co-polymer, block polymer, or block co-polymer derived from a lactam.

4 . The coating composition of claim 3 , wherein the polymeric binder comprises a polylactam of Formula (1):

wherein R 1 , R 2 , R3, and R 4 can be alkyl or aromatic substituents and R 5 can be alkyl, aryl, or fused ring; and
wherein the preferred polylactam can be a homopolymer or a co-polymer where co-polymeric group X can be a 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, preferably between 2 and 4, and wherein the ratio of 1 to n is such that 0≤1:n≤10 or 0≤1:n≤1.

5 . The coating composition of claim 3 , wherein the homopolymer or co-polymer derived from a lactam is at least one selected from the group consisting of polyvinylpyrrolidone (PVP), polyvinylcaprolactam (PVCap), and polyvinyl-valerolactam.

6 . The coating composition of claim 5 , wherein the homopolymer or co-polymer derived from a lactam is polyvinylpyrrolidone (PVP).

7 . The coating composition of claim 5 , wherein the homopolymer or co-polymer derived from a lactam is polyvinylcaprolactam (PVCap).

8 . The coating composition of claim 5 , wherein the homopolymer or co-polymer derived from a lactam is polyvinyl-valerolactam.

9 . The coating composition of claim 3 , wherein the polymeric coating comprises a polylactam according to Formula (2) and a catalyst:

wherein R 1 , R 2 , R 3 , and R 4 can be alkyl or aromatic substituents;
R 5 can be alkyl, aryl, or fused ring;
m can be an integer between 1 and 10, preferably between 2 and 4,
and wherein the ratio of 1 to n is such that 0≤1:n≤10 or 0≤1:n≤1,
and X is an epoxide or an alkyl amine.

10 . The coating composition of claim 9 , wherein X is an epoxide and the catalyst comprises an alkyl amine.

11 . The coating composition of claim 9 , wherein X is an alkyl amine and the catalyst comprises an epoxide.

12 . The coating composition of claim 2 , wherein the polymeric binder comprises polyvinyl alcohol (PVA).

13 . The coating composition of claim 2 , wherein the polymeric binder comprises polyacrylic acid (PAA).

14 . The coating composition of claim 2 , wherein the polymeric binder comprises Polyvinyl acetate (PVAc).

15 . The coating composition of claim 2 , wherein the polymeric binder comprises carboxymethyl cellulose (CMC), an isobutylene polymer, or a combination thereof.

16 . The coating composition of claim 2 , wherein the polymeric binder comprises an acrylic resin.

17 . The coating composition of claim 2 , wherein the polymeric binder comprises latex.

18 . The coating composition of claim 1 , wherein the polymeric binder comprises water as the solvent.

19 . The coating composition of claim 1 , wherein the polymeric binder comprises an aqueous solvent, which is a mixture comprising more than 50% water and a non-aqueous solvent.

20 . The coating composition of claim 19 , wherein the aqueous solvent comprises more than 90% water.

21 . The coating composition of claim 1 , wherein the polymeric binder comprises a non-aqueous solvent.

22 . The coating composition of claim 1 , wherein the heat-resistant particles comprise materials that are heat-resistant at a temperature of 200° C. or higher, meaning that the material does not undergo substantial physical changes, such as deformation, at temperatures of 200° C. or higher.

23 . The coating composition of claim 1 , wherein the heat-resistant particles comprise at least one of an organic material, an inorganic material, or mixture of an organic material and an inorganic material.

24 . The coating composition of claim 23 , 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, a polydivinylbenzene (PDVB) resin, carbon black, and graphite.

25 . The coating composition of claim 23 , wherein the heat-resistant particles comprise an inorganic material or a mixture of an inorganic material and an organic material, and the inorganic material is at least one selected from the group consisting of: iron oxides, silicon dioxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), boehmite (Al(O)OH), zirconium dioxide (ZrO 2 ), titanium dioxide (TiO 2 ), barium sulfate (BaSO 4 ), barium titanium oxide (BaTiO 3 ), aluminum nitride, silicon nitride, calcium fluoride, barium fluoride, zeolite, apatite, kaoline, mullite, spinel, olivine, mica, tin dioxide (SnO 2 ), indium tin oxide, and oxides of transition metals.

26 . The coating composition of 23 , wherein the heat-resistant particles have an average particle size of 0.01 to 5 microns.

27 . The coating composition of 26 , wherein the heat-resistant particles have an average particle size of from 0.03 to 3 microns.

28 . The coating composition of claim 26 , wherein the heat-resistant particles have an average particle size of 0.01 to 2 microns.

29 . The coating composition of claim 1 , wherein the ratio of heat-resistant particles to binder in the coating composition is 50:50 to 99:1.

30 . The coating composition of claim 29 , wherein the ratio of heat-resistant particles to binder is 70:30 to 99:1.

31 . The coating composition of claim 30 , wherein the ratio or heat-resistant particles to binder is 90:10 to 99:1.

32 . The coating composition of claim 31 , wherein the ratio of heat-resistant particles to binder is 90:10 to 98:2.

33 . The coating composition of claim 1 , wherein at least one of the heat-resistant pa

Assignees

• Celgard Llc

Inventors

• Lane Michael B
• Jeon Insik
• Kruger Edward
• Yu Xiang
• Smith Ronnie E
• Reinartz Stefan
• Ma Junqing

Classifications

• C09D7/65 Primary

  macromolecular (C09D7/41-C09D7/48 take precedence) · CPC title

• H01M50/461

  with adhesive layers between electrodes and separators · CPC title

• H01M50/457

  comprising three or more layers · CPC title

• H01M50/451

  comprising layers of only organic material and layers containing inorganic material · CPC title

• H01M50/426

  Fluorocarbon polymers · CPC title