US2021043904A1PendingUtilityA1

Co-extruded, multi-layered battery separator

69
Assignee: CELGARD LLCPriority: Nov 17, 2006Filed: Oct 26, 2020Published: Feb 11, 2021
Est. expiryNov 17, 2026(~0.3 yrs left)· nominal 20-yr term from priority
Inventors:Ronald W. CallC. William Fulk, Jr.Lie ShiXiaomin ZhangKhuy V. Nguyen
B29C 48/32H01M 50/494H01M 50/457H01M 50/491H01M 50/417H01M 50/489H01M 50/414H01M 50/449H01M 10/0525Y02E60/10B29K 2105/0032B29K 2027/08B29K 2081/04B29K 2105/256B29K 2023/065B29C 48/21B29K 2027/18B29C 48/17B29C 48/307B29K 2027/16B29K 2023/06B29K 2067/006B29C 48/0018B29K 2029/04B29K 2023/12B29K 2105/0026B29K 2077/00B29L 2028/00B29K 2105/04B29C 48/022B29K 2105/0008B29K 2105/06B29K 2059/00B29K 2023/0633B29L 2009/00B29C 48/08B29K 2105/16B29C 48/16B29C 48/305B29C 48/13B29K 2067/00B29K 2023/0683B29C 48/0012B29K 2031/00B29K 2023/0625B29C 48/30B29C 48/10H01M 2/1653H01M 2/1686
69
PatentIndex Score
0
Cited by
0
References
0
Claims

Abstract

A battery separator comprises a co-extruded, microporous membrane having at least two layers made of extrudable polymers and having: a uniform thickness defined by a standard deviation of <0.80 microns (μm); or an interply adhesion as defined by a peel strength >60 grams.

Claims

exact text as granted — not AI-modified
1 . A battery separator comprising:
 a co-extruded, microporous membrane having at least two layers made of extrudable polymers and having a uniform thickness defined by a standard deviation of <0.80 μm, wherein the co-extruded, microporous membrane has a thickness from 8 to 25 microns.   
     
     
         2 . (canceled) 
     
     
         3 . (canceled) 
     
     
         4 . The battery separator of  claim 1  wherein an extrudable polymer of one of said at least two layers is the same or different than an extrudable polymer of another of said at least two layers. 
     
     
         5 . The battery separator according to  claim 1  wherein at least one of said extrudable polymers is a thermoplastic polymer. 
     
     
         6 . The battery separator according to  claim 1  wherein at least one of said extrudable polymers is selected from the group consisting of: polyolefins, polyamides, polyvinylidenes, copolymers of the foregoing, and blends thereof. 
     
     
         7 . The battery separator according to  claim 1  wherein at least one of said extrudable polymers further comprises a material added thereto. 
     
     
         8 . The battery separator according to  claim 7  wherein said material is selected from the group of materials adapted to do at least one of the following: lower the melting temperature of the extrudable polymers; improve the melt integrity of the membrane; improve the strength of toughness of the membrane; improve the antistatic properties of the membrane; improve the surface wettability of the separator; improve the surface tribology performance of the separator; improve the processing of the extrudable polymers; improve the flame of the membrane; facilitate nucleation of the extrudable polymers; color the layer of the membrane; and combinations thereof. 
     
     
         9 . A battery separator comprising:
 a co-extruded, microporous membrane having at least two layers made of extrudable polymers and having an interply adhesion as defined by a peel strength >60 grams.   
     
     
         10 . The battery separator according to  claim 9  wherein at least one of said extrudable polymers is a thermoplastic polymer. 
     
     
         11 . The battery separator of  claim 9  wherein an extrudable polymer of one of said at least two layers is the same or different than an extrudable polymer of another of said at least two layers. 
     
     
         12 . The battery separator according to  claim 9  wherein at least one of said extrudable polymers is selected from the group consisting of: polyolefins, polyacetals, polyamides, polyesters, polysulfides, polyvinyl alcohols, polyvinyl esters, polyvinylidenes, copolymers of the foregoing, and blends thereof. 
     
     
         13 . The battery separator according to  claim 9  wherein at least one of said extrudable polymers further comprises a material added thereto. 
     
     
         14 . The battery separator according to  claim 13  wherein said material is selected from the group of materials adapted to do at least one of the following: lower the melting temperature of the extrudable polymers; improve the melt integrity of the membrane; improve the strength of toughness of the membrane; improve the antistatic properties of the membrane; improve the surface wettability of the separator; improve the surface tribology performance of the separator; improve the processing of the extrudable polymers; improve the flame retardancy of the membrane; facilitate nucleation of the extrudable polymers; color the layer of the membrane; and combinations thereof. 
     
     
         15 .- 18 . (canceled) 
     
     
         19 . The battery separator according to  claim 1  wherein said membrane is a dry-stretched membrane. 
     
     
         20 . The battery separator according to  claim 9  wherein said membrane is a dry-stretched membrane. 
     
     
         21 . A lithium ion battery comprising the battery separator of  claim 1 . 
     
     
         22 . A lithium ion battery comprising the battery separator of  claim 9 . 
     
     
         23 . (canceled) 
     
     
         24 . The battery separator of  claim 4  wherein the extrudable polymer of one of said at least two layers is different than an extrudable polymer of another of said at least two layers, and wherein dissimilar polymer refers to: polymers having dissimilar chemical natures (e.g., PE and PP, or PE and a co-polymer of PE are polymers having dissimilar chemical natures), and/or polymer having the same chemical nature (e.g., PP1 and PP2, or PP and a co-polymer of PP are polymers having similar chemical natures) but dissimilar properties (e.g., two PE's or PP's having differing properties (e.g., density, molecular weights, molecular weight distributions, rheology, additives (composition and/or percentage), etc.). 
     
     
         25 . The battery separator of  claim 4  wherein an extrudable polymer of one of said at least two layers is polymerically dissimilar from an extrudable polymer of another of said at least two layers. 
     
     
         26 . The battery separator of  claim 4 , wherein the extrudable polymer of the one of said at least two layers comprises a first polypropylene, and wherein the extrudable polymer of the another of said at least two layers comprises a second polypropylene, said second polypropylene having a density, molecular weight, molecular weight distribution, rheology, additives (composition and/or percentage), and/or the like different from said first polypropylene. 
     
     
         27 . The battery separator of  claim 11  wherein the extrudable polymer of one of said at least two layers is different than an extrudable polymer of another of said at least two layers, and wherein dissimilar polymer refers to: polymers having dissimilar chemical natures (e.g., PE and PP, or PE and a co-polymer of PE are polymers having dissimilar chemical natures), and/or polymer having the same chemical nature (e.g., PP1 and PP2, or PP and a co-polymer of PP are polymers having similar chemical natures) but dissimilar properties (e.g., two PE's or PP's having differing properties (e.g., density, molecular weights, molecular weight distributions, rheology, additives (composition and/or percentage), etc.). 
     
     
         28 . The battery separator of  claim 11  wherein an extrudable polymer of one of said at least two layers is polymerically dissimilar from an extrudable polymer of another of said at least two layers. 
     
     
         29 . The battery separator of  claim 11 , wherein the extrudable polymer of the one of said at least two layers comprises a first polypropylene, and wherein the extrudable polymer of the another of said at least two layers comprises a second polypropylene, said second polypropylene having a density, molecular weight, molecular weight distribution, rheology, additives (composition and/or percentage), and/or the like different from said first polypropylene. 
     
     
         30 . The battery separator according to  claim 4  wherein said membrane is a dry-stretched membrane. 
     
     
         31 . The battery separator according to  claim 11  wherein said membrane is a dry-stretched membrane. 
     
     
         32 . A lithium ion battery comprising the battery separator of  claim 4 . 
     
     
         33 . A lithium ion battery comprising the battery separator of  claim 11 . 
     
     
         34 . A membrane comprising:
 a co-extruded, microporous membrane having at least two layers made of extrudable polymers and having a uniform thickness defined by a standard deviation of <0.80 μm, wherein the co-extruded, microporous membrane has a thickness from 8 to 25 microns.   
     
     
         35 . The membrane of  claim 34  wherein an extrudable polymer of one of said at least two layers is the same or different than an extrudable polymer of another of said at least two layers. 
     
     
         36 . The membrane according to  claim 34  wherein at least one of said extrudable polymers is a thermoplastic polymer. 
     
     
         37 . The membrane according to  claim 34  wherein at least one of said extrudable polymers is selected from the group consisting of: polyolefins, polyvinylidenes, copolymers of the foregoing, and blends thereof. 
     
     
         38 . The membrane according to  claim 34  wherein at least one of said extrudable polymers further comprises a material added thereto. 
     
     
         39 . The membrane according to  claim 38  wherein said material is selected from the group of materials adapted to do at least one of the following: lower the melting temperature of the extrudable polymers; improve the melt integrity of the membrane; improve the strength of toughness of the membrane; improve the antistatic properties of the membrane; improve the surface wettability of the separator; improve the surface tribology performance of the separator; improve the processing of the extrudable polymers; improve the flame of the membrane; facilitate nucleation of the extrudable polymers; color the layer of the membrane; and combinations thereof. 
     
     
         40 . A membrane comprising:
 a co-extruded, microporous membrane having at least two layers made of extrudable polymers and having an interply adhesion as defined by a peel strength >60 grams.   
     
     
         41 . The membrane according to  claim 40  wherein at least one of said extrudable polymers is a thermoplastic polymer. 
     
     
         42 . The membrane of  claim 40  wherein an extrudable polymer of one of said at least two layers is the same or different than an extrudable polymer of another of said at least two layers. 
     
     
         43 . The membrane according to  claim 40  wherein at least one of said extrudable polymers is selected from the group consisting of: polyolefins, polyacetals, polyamides, polyesters, polysulfides, polyvinyl alcohols, polyvinyl esters, polyvinylidenes, copolymers of the foregoing, and blends thereof. 
     
     
         44 . The membrane according to  claim 40  wherein at least one of said extrudable polymers further comprises a material added thereto. 
     
     
         45 . The membrane according to  claim 44  wherein said material is selected from the group of materials adapted to do at least one of the following: lower the melting temperature of the extrudable polymers; improve the melt integrity of the membrane; improve the strength of toughness of the membrane; improve the antistatic properties of the membrane; improve the surface wettability of the separator; improve the surface tribology performance of the separator; improve the processing of the extrudable polymers; improve the flame retardancy of the membrane; facilitate nucleation of the extrudable polymers; color the layer of the membrane; and combinations thereof. 
     
     
         46 . The membrane according to  claim 34  wherein said membrane is a dry-stretched membrane. 
     
     
         47 . The membrane according to  claim 40  wherein said membrane is a dry-stretched membrane. 
     
     
         48 . A lithium ion battery comprising the membrane of  claim 34 . 
     
     
         49 . A lithium ion battery comprising the membrane of  claim 40 . 
     
     
         50 . The membrane of  claim 35  wherein the extrudable polymer of one of said at least two layers is different than an extrudable polymer of another of said at least two layers, and wherein dissimilar polymer refers to: polymers having dissimilar chemical natures (e.g., PE and PP, or PE and a co-polymer of PE are polymers having dissimilar chemical natures), and/or polymer having the same chemical nature (e.g., PP1 and PP2, or PP and a co-polymer of PP are polymers having similar chemical natures) but dissimilar properties (e.g., two PE's or PP's having differing properties (e.g., density, molecular weights, molecular weight distributions, rheology, additives (composition and/or percentage), etc.). 
     
     
         51 . The membrane of  claim 35  wherein an extrudable polymer of one of said at least two layers is polymerically dissimilar from an extrudable polymer of another of said at least two layers. 
     
     
         52 . The membrane of  claim 35 , wherein the extrudable polymer of the one of said at least two layers comprises a first polypropylene, and wherein the extrudable polymer of the another of said at least two layers comprises a second polypropylene, said second polypropylene having a density, molecular weight, molecular weight distribution, rheology, additives (composition and/or percentage), and/or the like different from said first polypropylene. 
     
     
         53 . The membrane of  claim 42  wherein the extrudable polymer of one of said at least two layers is different than an extrudable polymer of another of said at least two layers, and wherein dissimilar polymer refers to: polymers having dissimilar chemical natures (e.g., PE and PP, or PE and a co-polymer of PE are polymers having dissimilar chemical natures), and/or polymer having the same chemical nature (e.g., PP1 and PP2, or PP and a co-polymer of PP are polymers having similar chemical natures) but dissimilar properties (e.g., two PE's or PP's having differing properties (e.g., density, molecular weights, molecular weight distributions, rheology, additives (composition and/or percentage), etc.). 
     
     
         54 . The membrane of  claim 42  wherein an extrudable polymer of one of said at least two layers is polymerically dissimilar from an extrudable polymer of another of said at least two layers. 
     
     
         55 . The membrane of  claim 42 , wherein the extrudable polymer of the one of said at least two layers comprises a first polypropylene, and wherein the extrudable polymer of the another of said at least two layers comprises a second polypropylene, said second polypropylene having a density, molecular weight, molecular weight distribution, rheology, additives (composition and/or percentage), and/or the like different from said first polypropylene. 
     
     
         56 . The membrane according to  claim 35  wherein said membrane is a dry-stretched membrane. 
     
     
         57 . The membrane according to  claim 42  wherein said membrane is a dry-stretched membrane. 
     
     
         58 . A lithium ion battery comprising the membrane of  claim 35 . 
     
     
         59 . A lithium ion battery comprising the membrane of  claim 42 .

Join the waitlist — get patent alerts

Track US2021043904A1 — get alerts on status changes and closely related new filings.

We store only your email — no account needed. See our privacy policy.