US2022166107A1PendingUtilityA1
Battery separators with controlled pore structure
Est. expiryNov 21, 2034(~8.4 yrs left)· nominal 20-yr term from priority
H01M 50/494H01M 50/489H01M 50/491H01M 50/437H01M 10/12Y02P70/50Y02E60/10H01M 50/44H01M 50/431
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Claims
Abstract
Disclosed are battery separators comprising glass fibers and having a basis weight (gsm), a specific surface area (m 2 /g), a density (gsm/mm) and a mean pore size (μm), which satisfy the equation disclosed herein, provided that: the specific surface area is less than 1.5 m 2 /g, or the density is greater than 180 gsm/mm. Also disclosed are batteries comprising the battery separators, and processes for making the separators.
Claims
exact text as granted — not AI-modifiedWhat is claimed is:
1 . A battery separator comprising fibers, wherein the fibers comprise at least 5% glass fibers, and having a basis weight (in gsm), a specific surface area (in m 2 /g), a density (in gsm/mm) and a mean pore size (in μm), wherein the following equation is satisfied:
mean
pore
size
<
(
2
7
0
basis
weight
)
0
.
5
3
*
1
.
6
specific
surface
area
*
(
6
5
density
-
1.8
)
,
wherein:
the battery separator has an acid filling time of less than or equal to 500 seconds; and
the battery separator has a thickness greater than about 1 mm when loaded to a force of 20 kPa.
2 . A battery separator comprising fibers, wherein the fibers comprise at least 5% glass fibers, and having a basis weight (in gsm), a specific surface area (in m 2 /g), a density (in gsm/mm) and a mean pore size (in μm), wherein the following equation is satisfied:
mean
pore
size
<
(
2
7
0
basis
weight
)
0
.
5
3
*
1
.
6
specific
surface
area
*
(
6
5
density
-
1.8
)
,
wherein:
the battery separator has a wet tensile strength of greater than or equal to 0.01 kN/m; and
the battery separator has a thickness greater than about 1 mm when loaded to a force of 20 kPa.
3 . A battery separator comprising fibers, wherein the fibers comprise at least 5% glass fibers, and having a basis weight (in gsm), a specific surface area (in m 2 /g), a density (in gsm/mm) and a mean pore size (in μm), wherein the following equation is satisfied:
mean
pore
size
<
(
2
7
0
basis
weight
)
0
.
5
3
*
1
.
6
specific
surface
area
*
(
6
5
density
-
1.8
)
,
wherein:
the battery separator has an acid filling time of less than or equal to 500 seconds;
the battery separator has a percent compression of less than 31% when measured according to Battery Council International Battery Technical Manual BCIS-03 (Rev. September 9) method number 1, and
the percent compression is equal to ((T@10 kPa-T@100 kPa)/T@10 kPa)*100% wherein T@ 10 kPa is a thickness of the battery separator at 10 kPa and wherein T@100 kPa is a thickness of the battery at 100 kPa.
4 . A battery separator comprising fibers, wherein the fibers comprise at least 5% glass fibers, and having a basis weight (in gsm), a specific surface area (in m 2 /g), a density (in gsm/mm) and a mean pore size (in μm), wherein the following equation is satisfied:
mean
pore
size
<
(
2
7
0
basis
weight
)
0
.
5
3
*
1
.
6
specific
surface
area
*
(
6
5
density
-
1.8
)
,
wherein:
the battery separator has a wet tensile strength of greater than or equal to 0.01 kN/m;
the battery separator has a percent compression of less than 31% when measured according to Battery Council International Battery Technical Manual BCIS-03 (Rev. September 9) method number 1, and
the percent compression is equal to ((T@10 kPa-T@100 kPa)/T@10 kPa)*100% wherein T@ 10 kPa is a thickness of the battery separator at 10 kPa and wherein T@100 kPa is a thickness of the battery at 100 kPa.
5 . The battery separator of claim 1 , wherein the specific surface area is less than 2.0 m 2 /g.
6 . The battery separator of claim 1 , wherein the specific surface area is greater than 1.4 m 2 /g.
7 . The battery separator of claim 1 , wherein the fibers comprise about 5% to about 50% fibers having an average diameter less than or equal to 1.0 μm.
8 . The battery separator of claim 7 , wherein the fibers further comprise fibers having an average fiber diameter of greater than 2 microns.
9 . The battery separator of claim 1 , wherein fibers having an average fiber diameter of greater than or equal to 1 micron and less than or equal to 2 microns make up greater than or equal to 20 wt % and less than or equal to 100 wt % of the battery separator.
10 . The battery separator of claim 1 , wherein glass fibers make up 100 wt % of the fibers in the battery separator.
11 . The battery separator of claim 1 , wherein the fibers comprise synthetic fibers.
12 . The battery separator of claim 11 , wherein the synthetic fibers comprise bicomponent fibers.
13 . The battery separator of claim 1 , wherein the mean pore size is less than 6 μm.
14 . The battery separator of claim 1 , wherein the density is about 175 gsm/mm to about 400 gsm/mm.
15 . The battery separator of claim 1 , wherein the basis weight is between 150 gsm and 1000 gsm.
16 . The battery separator of claim 1 , wherein the battery separator has a percent recovery, when compressed from 10 kPa to 100 kPa and recovered to 10 kPa, of greater than 84% when measured according to Battery Council International Battery Technical Manual BCIS-03 (Rev. September 9) method number 1, and wherein the percent recovery is equal to (T rec /T comp )*100%, where T comp is the thickness of the battery separator at 20 kPa during compression and wherein T rec is the thickness at 20 kPa during recovery.
17 . The battery separator of claim 1 , wherein the fibers comprise about 5% to about 50% fibers having an average diameter less than or equal to 1.0 μm, wherein the mean pore size is less than 6 μm, wherein the density is about 175 gsm/mm to about 400 gsm/mm, and wherein the basis weight is between 150 gsm and 1000 gsm.
18 . The battery separator of claim 1 , wherein the fibers comprise about 15% to about 30% fibers having an average diameter less than or equal to 1.0 μm, wherein the mean pore size is less than 6 μm, wherein the density is about 175 gsm/mm to about 400 gsm/mm, and wherein the basis weight is between 150 gsm and 500 gsm.
19 . The battery separator of claim 1 , wherein the fibers comprise about 5% to about 50% fibers having an average diameter less than or equal to 1.0 μm, wherein the mean pore size is less than 6 μm, wherein the density is about 175 gsm/mm to about 400 gsm/mm, and wherein the basis weight is between 150 gsm and 1000 gsm.
20 . The battery separator of claim 1 , wherein the fibers comprise about 15% to about 30% fibers having an average diameter less than or equal to 1.0 μm, wherein the mean pore size is less than 6 μm, wherein the density is about 175 gsm/mm to about 400 gsm/mm, and wherein the basis weight is between 150 gsm and 500 gsm.Cited by (0)
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