Ultra-thin ceramic coating on separator for batteries

Patent metadata

Field	Value
Publication number	US-2023170580-A1
Application number	US-202318101159-A
Country	US
Kind code	A1
Filing date	Jan 25, 2023
Priority date	Aug 21, 2018
Publication date	Jun 1, 2023
Grant date	—

Abstract

Implementations of the present disclosure generally relate to separators, high performance electrochemical devices, such as, batteries and capacitors, including the aforementioned separators, systems and methods for fabricating the same. In one implementation, a separator is provided. The separator comprises a polymer substrate, capable of conducting ions, having a first surface and a second surface opposing the first surface. The separator further comprises a first ceramic-containing layer, capable of conducting ions, formed on the first surface. The first ceramic-containing layer has a thickness in a range from about 1,000 nanometers to about 5,000 nanometers. The separator further comprises a second ceramic-containing layer, capable of conducting ions, formed on the second surface. The second ceramic-containing layer is a binder-free ceramic-containing layer and has a thickness in a range from about 1 nanometer to about 1,000 nanometers.

First claim

1 . A separator, comprising:
a polymer substrate, capable of conducting ions, having a first surface and a second surface opposing the first surface; a first ceramic-containing layer, capable of conducting ions, formed on the first surface; and a second ceramic-containing layer, capable of conducting ions, formed on the second surface, wherein the second ceramic-containing layer is a binder-free ceramic-containing layer and has a thickness in a range from about 1 nanometer to about 1,000 nanometers.

2 . The separator of claim 1 , wherein the polymer substrate is a microporous ion-conducting polymeric layer.

3 . The separator of claim 1 , wherein each of the first ceramic-containing layer and the second ceramic-containing layer independently comprises a material selected from porous aluminum oxide, porous-ZrO 2 , porous-HfO 2 , porous-SiO 2 , porous-MgO, porous-TiO 2 , porous-Ta 2 O 5 , porous-Nb 2 O 5 , porous-LiAlO 2 , porous-BaTiO 3 , ion-conducting garnet, anti-ion-conducting perovskites, porous glass dielectric, or combinations thereof.

4 . The separator of claim 1 , wherein the first ceramic-containing layer comprises a binder.

5 . The separator of claim 1 , wherein the second ceramic-containing layer has a thickness in the range from about 50 nanometers to about 500 nanometers.

6 . The separator of claim 1 , wherein the first ceramic-containing layer has a thickness in the range from about 1,000 nanometers and 5,000 nanometers.

7 . The separator of claim 1 , wherein the polymer substrate has a thickness in a range from about 3 microns to about 25 microns.

8 . The separator of claim 1 , wherein the polymer substrate is a polyolefenic membrane.

9 . The separator of claim 8 , wherein the polyolefinic membrane is a polyethylene membrane or a polypropylene membrane.

10 . The separator of claim 1 , wherein the second ceramic-containing layer comprises porous aluminum oxide.

11 . The separator of claim 10 , wherein the second ceramic-containing layer further comprises zirconium oxide, silicon oxide, or combinations thereof.

12 . The separator of claim 1 , further comprising a third ceramic-containing layer disposed on the second ceramic-containing layer.

13 . The separator of claim 12 , wherein the third ceramic-containing layer comprises silicon oxide.

14 . The separator of claim 12 , wherein the third ceramic-containing layer is binder-free.

15 . The separator of claim 12 , wherein the third ceramic-containing layer has a thickness in a range from about 1 nanometer to about 100 nanometers.

16 . The separator of claim 1 , further comprising a fourth ceramic-containing layer disposed on the third ceramic-containing layer.

17 . The separator of claim 16 , wherein the fourth ceramic-containing layer comprises zirconium oxide, is binder-free, and has a thickness in a range from about 1 nanometer to about 100 nanometers.

18 . A separator, comprising:
a polymer substrate, capable of conducting ions, having a first surface and a second surface opposing the first surface; a first ceramic-containing layer, capable of conducting ions, formed on the first surface, wherein the first ceramic-containing layer has a thickness in a range from about 1,000 nanometers to about 5,000 nanometers; a second ceramic-containing layer, capable of conducting ions, formed on the second surface, wherein the second ceramic-containing layer is a binder-free ceramic-containing layer and has a thickness in a range from about 1 nanometer to about 1,000 nanometers; and a third ceramic-containing layer disposed on the second ceramic-containing layer.

19 . The separator of claim 18 , wherein the third ceramic-containing layer is binder-free and has a thickness in a range from about 1 nanometer to about 100 nanometers.

20 . A separator, comprising:
a polymer substrate, capable of conducting ions, having a first surface and a second surface opposing the first surface; a first ceramic-containing layer, capable of conducting ions, formed on the first surface; a second ceramic-containing layer, capable of conducting ions, formed on the second surface, wherein the second ceramic-containing layer is a binder-free ceramic-containing layer; and a third ceramic-containing layer disposed on the second ceramic-containing layer, wherein the third ceramic-containing layer is binder-free.

Assignees

• Applied Materials Inc

Inventors

• Wang Connie P
• Si Wen
• Sim Yin Let
• Dieter Torsten
• Trassl Roland
• Herle Subramanya P
• Daube Christoph
• Zhu Jian
• Cushing James

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M50/489

  Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties · CPC title

• H01M10/052

  Li-accumulators · CPC title

• H01M50/451 Primary

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

• H01M50/434

  Ceramics · CPC title