US2017263904A1PendingUtilityA1

Methods for forming ionically conductive composite separators

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Assignee: FORD GLOBAL TECH LLCPriority: Oct 2, 2014Filed: May 15, 2017Published: Sep 14, 2017
Est. expiryOct 2, 2034(~8.2 yrs left)· nominal 20-yr term from priority
Inventors:Venkataramani AnandanAndrew Robert DrewsJohn Matthew Ginder
H01M 10/056H01M 2300/0088H01M 2300/0068H01M 10/14H01M 2300/0082H01M 2010/4271H01M 10/052H01M 50/497H01M 50/443H01M 50/403H01M 2/145H01M 2/166H01M 2/20H01M 2/18H01M 50/463Y02P70/50H01M 50/446Y02E60/10
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Claims

Abstract

A method of forming a conductive composite separator. The method includes providing a plurality of particles within a bulk separator material; and applying an AC electric field to the particles and the bulk separator material while the bulk separator material is in a liquid state to align the particles into at least one ionically conductive aligned particle region within the bulk separator material.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
         1 . A method of forming a conductive composite separator, comprising:
 providing a plurality of particles within a bulk separator material; and   applying an AC electric field to the particles and the bulk separator material while the bulk separator material is in a liquid state to align the particles into at least one ionically conductive aligned particle region within the bulk separator material.   
     
     
         2 . The method of  claim 1 , wherein the AC electric field has a strength of 100 to 2,000 V/mm and a frequency of 10 Hz to 10 kHz. 
     
     
         3 . The method of  claim 1 , wherein the electric field is applied for 1 second to 1 hour. 
     
     
         4 . The method of  claim 1  further comprising heating the bulk material such that it is in a liquid state prior to the applying step. 
     
     
         5 . The method of  claim 1 , wherein the at least one ionically conductive aligned particle region extends in a straight line parallel to a thickness of the bulk separator material. 
     
     
         6 . The method of  claim 1 , wherein a volume fraction of particles in the at least one ionically conductive aligned particle region is at least 90%. 
     
     
         7 . The method of  claim 1 , wherein the bulk separator material includes polyethylene oxide (PEO), polyethylene-glycol (PEG), polymethylmethacrylate (PMMA), or polyacrylonitrile (PAN). 
     
     
         8 . A method of forming an ionically conductive composite separator, comprising:
 providing a plurality of particles within an ionically conductive polymer bulk separator material; and   applying an AC electric field to the particles and the bulk separator material while the bulk separator material is in a liquid state to align the particles into at least one ionically conductive aligned particle region within the bulk separator material.   
     
     
         9 . The method of  claim 8 , wherein the at least one ionically conductive aligned particle region is an at least one ionically conductive aligned solid particle region. 
     
     
         10 . The method of  claim 8 , wherein the AC electric field has a strength of 100 to 2,000 V/mm and a frequency of 10 Hz to 10 kHz. 
     
     
         11 . The method of  claim 8 , wherein the electric field is applied for 1 second to 1 hour. 
     
     
         12 . The method of  claim 8  further comprising heating the bulk material such that it is in a liquid state prior to the applying step. 
     
     
         13 . The method of  claim 8 , wherein the at least one ionically conductive aligned particle region extends in a straight line parallel to a thickness of the bulk separator material. 
     
     
         14 . The method of  claim 8 , wherein a volume fraction of particles in the at least one ionically conductive aligned particle region is at least 90%. 
     
     
         15 . A method of forming a conductive composite separator, comprising:
 providing a plurality of particles within a bulk separator material; and   dielectrophoretic aligning the particles into at least one ionically conductive aligned particle region within the bulk separator material while the bulk separator material is in a liquid state to align.   
     
     
         16 . The method of  claim 15  further comprising heating the bulk material such that it is in a liquid state prior to the dielectrophoretic aligning step. 
     
     
         17 . The method of  claim 15 , wherein the dielectrophoretic aligning step includes applying an electric field to the particles and the bulk separator material. 
     
     
         18 . The method of  claim 17  further comprising controlling the strength and/or frequency of the electric field. 
     
     
         19 . The method of  claim 17 , wherein the electric field is an AC electric field. 
     
     
         20 . The method of  claim 19 , wherein the AC electric field has a strength of 100 to 2,000 V/mm and a frequency of 10 Hz to 10 kHz.

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