Gas phase deposition of battery separators

Patent metadata

Field	Value
Publication number	US-9647259-B2
Application number	US-201314069125-A
Country	US
Kind code	B2
Filing date	Oct 31, 2013
Priority date	Mar 19, 2009
Publication date	May 9, 2017
Grant date	May 9, 2017

Abstract

Methods of making a battery component are provided. The method comprises gas phase depositing a composition onto an electrode, the composition comprising a first component and a second component, and removing at least a portion of the second component to form a separator comprising a porous polymer film on the electrode. The first component is selected from the group consisting of polymers, dimers and monomers. In some embodiments, the second component is selected from the group consisting of polymers, dimers and monomers and is different from the first component. The first component and the second component each form separate polymer phases and together form a layer. In some embodiments, the second component is selected from the group consisting of by-products and remaining portions of the first component from the forming the first polymer.

First claim

What is claimed is:

1. A method of making a battery component comprising:
gas phase depositing a composition onto an electrode, the composition comprising a first component selected from the group consisting of polymers, dimers and monomers, and a second component selected from the group consisting of polymers, dimers and monomers, the first component being different than the second component, the first component and the second component each form separate polymer phases and together form a layer;
removing at least a portion of the second component to form a separator comprising a porous polymer film on the electrode, wherein the porous polymer film is a porous poly(para-xylylene) film having an open cell structure; and
cross-linking the porous polymer film.

2. The method of claim 1 , further comprising:
activating a first dimer; and
pyrolysing the first dimer to form the first component.

3. The method of claim 2 , further comprising:
activating a second dimer; and
pyrolysing the second dimer to form the second component.

4. The method of claim 2 , wherein the first dimer comprises di-para-xylylene, the first component comprises para-xylylene, and the polymers of the first component comprise parylene.

5. The method of claim 1 , wherein the gas phase depositing comprises atomic layer deposition.

6. The method of claim 1 , wherein the gas phase depositing comprises plasma deposition.

7. The method of claim 1 , wherein the gas phase depositing further comprises reducing the electrode temperature to below room temperature.

8. The method of claim 1 , wherein the cross-linking the porous polymer film comprises using at least one cross-linking agent selected from the group consisting of N,N-methyl-bisacrylamide, 1,6-hexanediol diacrylate, trimethylolpropane triacrylate and ethylene glycol dimethacrylate.

9. The method of claim 1 , wherein the separator is a substantially conformal layer.

10. A method of making a battery component comprising:
activating a first dimer;
pyrolysing the firm dimer to form a first component;
gas phase depositing a composition onto an electrode, the composition comprising the first component selected from the group consisting of polymers, dimers and monomers, and a second component selected from the group consisting of polymers, dimers and monomers, the first component being different than the second component, the first component and the second component each form separate polymer phases and together form a layer, wherein the first dimer comprises di-para-xylylene, the first component comprises para-xylylene, and the polymers of the first component comprise parylene; and
removing at least a portion of the second component to form a separator comprising a porous polymer film on the electrode, wherein the porous polymer film is a porous poly(para-xylylene) film having an open cell structure.

11. The method of claim 10 , further comprising:
activating a second dimer; and
pyrolysing the second dimer to form the second component.

12. The method of claim 10 , wherein the gas phase depositing comprises atomic layer deposition.

13. The method of claim 10 , wherein the gas phase depositing comprises plasma deposition.

14. The method of claim 10 , wherein the gas phase depositing further comprises reducing the electrode temperature to below room temperature.

15. The method of claim 10 , wherein the separator is a substantially conformal layer.

16. A method of making a battery component comprising:
gas phase depositing a composition onto an electrode, the composition comprising a first component selected from the group consisting of polymers, dimers and monomers, and a second component selected from the group consisting of polymers, dimers and monomers, the first component being different than the second component, the first component and the second component each form separate polymer phases and together form a layer; and
removing at least a portion of the second component to form a separator comprising a porous polymer film on the electrode, wherein the porous polymer film is a porous poly(para-xylylene) film having an open cell structure,
wherein the gas phase depositing comprises atomic layer deposition or plasma deposition.

17. The method of claim 16 , wherein the gas phase depositing further comprises reducing the electrode temperature to below room temperature.

Assignees

• Enevate Corp

Inventors

• Park Benjamin Yong
• Gorkovenko Alexander
• Zaouk Rabih Bachir
• Schank Jr William Hubert

Classifications

• H01M50/414

  Synthetic resins, e.g. thermoplastics or thermosetting resins · CPC title

• H01M4/133 Primary

  Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx · CPC title

• H01M4/0471 Primary

  involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis · CPC title

• H01M2/16

  Electricity · mapped topic

• H01M4/583

  Carbonaceous material, e.g. graphite-intercalation compounds or CFx · CPC title