Coated separator and one-step method for preparing the same

Patent metadata

Field	Value
Publication number	US-9647254-B2
Application number	US-201414560322-A
Country	US
Kind code	B2
Filing date	Dec 4, 2014
Priority date	Dec 5, 2013
Publication date	May 9, 2017
Grant date	May 9, 2017

Abstract

In a one-step method for preparing a coated separator, a suspension of i) a ceramic, ii) a cermet, iii) a ceramic with an electrolyte, or iv) a cermet with an electrolyte in a carrier liquid is plasma sprayed without a carrier gas. The carrier liquid is water, alcohol, ethylene glycol, or mixtures thereof.

First claim

What is claimed is:

1. A one-step method for preparing a coated separator, the one step method comprising:
plasma spraying, without a carrier gas, a suspension of i) a ceramic with an electrolyte, or ii) a cermet with an electrolyte, in a carrier liquid of water, alcohol, ethylene glycol, or mixtures thereof, the suspension including a monomer selected from the group consisting of methyl methacrylate, acrylonitrile, vinyl chloride, and polyethylene glycol diacrylate.

2. The one-step method as defined in claim 1 wherein the suspension further includes a metal-organic precursor in isopropanol.

3. The one-step method as defined in claim 1 wherein the suspension further includes a polymeric complex.

4. The one-step method as defined in claim 1 wherein the suspension is introduced as a liquid stream into plasma jet used in the plasma spraying.

5. The one-step method as defined in claim 1 wherein the suspension is nebulized into droplets and then introduced into plasma jet used in the plasma spraying.

6. The one-step method as defined in claim 1 wherein the suspension further includes a dispersant.

7. The one-step method as defined in claim 1 wherein the plasma spraying is performed at a temperature less than or equal to 150° C.

8. The one-step method as defined in claim 1 wherein:
the suspension of i) the ceramic with the electrolyte includes a ceramic material and the electrolyte; or
the suspension of ii) the ceramic with the electrolyte includes a ceramic material, a metallic material, and the electrolyte.

9. The one-step method as defined in claim 8 wherein the plasma spraying forms a coating on a porous membrane, and wherein the method further comprises controlling a temperature of the plasma spraying to control a melting state of the ceramic material or the ceramic material and the metallic material.

10. The one-step method as defined in claim 9 wherein the ceramic material is at least partially melted, or the ceramic material and the metallic material are at least partially melted.

11. The one-step method as defined in claim 1 wherein the plasma spraying forms a coating on a porous membrane and wherein the carrier liquid in the suspension causes a cooling effect during plasma spraying, whereby a bond strength between the coating and the porous membrane is increased.

12. The one-step method as defined in claim 1 wherein the carrier liquid is water and wherein no external cooling mechanism is used in the one-step method.

13. The one-step method as defined in claim 1 wherein the plasma spraying forms a coating on a porous membrane and wherein the method further comprises adjusting a parameter of the plasma spraying to control a thickness of the coating such that the thickness ranges from about 0.1 μm to about 250 μm.

14. The one-step method as defined in claim 1 wherein the plasma spraying forms a coating on a porous membrane and wherein the method further comprises adjusting a parameter of the plasma spraying to control a porosity of the coating.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Dadheech Gayatri Vyas
• Cai Mei

Classifications

• C23C4/134 Primary

  Plasma spraying · CPC title

• H01M50/451

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

• H01M50/417

  Polyolefins · CPC title

• H01M50/434

  Ceramics · CPC title

• H01M50/437

  Glass · CPC title