Ceramic-Coated Battery Separator for Thermal Stability and Dendrite Resistance

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Solution Overview

Problem

Lithium-ion and lithium metal batteries face challenges in maintaining thermal, chemical, and physical stability under normal and abuse conditions, which can lead to undesirable events and chemical reactions, affecting their widespread commercialization.

Innovation Solution

A ceramic-based composite coating for battery separators is developed, comprising lithiated zeolite particles and a second ceramic material like aluminum oxide, silicon dioxide, or titanium dioxide, to enhance mechanical and thermal stability, while controlling moisture retention and providing resistance to mechanical damage and dendrite growth.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a coating is applied to enhance thermal and mechanical stability, then resistance to high temperatures and mechanical damage is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvethermal and mechanical stabilityVSAvoidcoating structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining lithiated zeolite particles with conventional ceramic particles (such as aluminum oxide, silicon dioxide, or titanium dioxide) in the coating formulation. This composite approach provides enhanced thermal stability and mechanical strength through the synergistic effects of different materials, while the use of conventional ceramics helps control costs and simplifies manufacturing compared to using only specialized materials.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The coating is applied selectively to specific surfaces of the battery separator, with different particle compositions or concentrations potentially used on different sides. The lithiated zeolite particles are distributed throughout the coating matrix to provide localized thermal management and mechanical reinforcement where most needed, rather than uniformly throughout the entire separator structure.

Inventive Principle:

Principle #3Local quality

2Reliability

If lithiated zeolite particles are used to improve thermal stability and moisture control, then battery safety is improved, but manufacturing cost increases

Engineering Contradiction:

Improvebattery safety and thermal stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines expensive lithiated zeolite particles with more cost-effective conventional ceramic particles in a composite coating formulation. This allows the battery to benefit from the superior thermal stability and moisture control properties of lithiated zeolite while the conventional ceramics provide structural support and cost reduction, making the overall manufacturing process more economically viable.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent optimizes the concentration and size distribution of lithiated zeolite particles within the coating to achieve the minimum effective amount needed for thermal stability and moisture control. By carefully controlling these parameters, the manufacturing cost is reduced while maintaining the necessary safety performance.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a thick coating is applied to resist dendrite growth and mechanical damage, then battery stability is improved, but energy density decreases due to increased mass

Engineering Contradiction:

Improvebattery stability and dendrite resistanceVSAvoidseparator mass

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The coating incorporates lithiated zeolite particles which possess porous structures that can effectively block dendrite growth pathways. These porous materials provide high surface area and effective barrier properties at thin coating thicknesses, preventing dendrite penetration without requiring thick coatings that would add excessive mass and reduce energy density.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The composite coating combines lithiated zeolite particles with conventional ceramic particles to create a lightweight yet mechanically robust barrier. The conventional ceramics provide structural integrity and mechanical strength, allowing the use of thinner coating layers that suffice for dendrite resistance, thereby minimizing added mass while maintaining battery stability.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The composite coating improves the stability and safety of lithium batteries by preventing mechanical damage, thermal collapse, and dendrite penetration, while reducing costs and maintaining energy density.

Implementation Method 1

the lithiated zeolite present within the ceramic-based composite coating is controlled based upon a desired moisture to be retained within the coated polymer separator

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS12620676B2System and method for a ceramic-based composite coating for a coated battery separator

Publication Date: 2026.05.05 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A coated polymer separator for a battery cell is provided. The coated polymer separator includes a polymer separator including a first primary surface and a second primary surface. The coated polymer separator further includes a ceramic-based composite coating disposed on the first primary surface and the second primary surface. The ceramic-based composite coating includes lithiated zeolite particles and particles of a second ceramic material including an oxide.