Ceramic-Coated Li-Ion Separator Membranes for High-Temperature Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lithium ion battery separators face challenges in safety, cycle life, and high temperature performance, particularly in secondary lithium ion batteries.
Innovation Solution
A microporous membrane coated with a ceramic coating and polymeric binders is applied to the separator, forming an oxidized or reduced interfacial layer that prevents further oxidation or reduction reactions, enhancing safety and high temperature performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ceramic coating is applied to the separator membrane, then safety and high temperature performance are improved, but device complexity increases
Solution Approach 1:
The patent applies a ceramic coating layer on top of a porous polymer membrane substrate to create a composite separator structure. This composite material approach combines the thermal stability and chemical inertness of ceramics with the porosity and flexibility of polymers, resolving the contradiction by improving safety through the ceramic layer while maintaining manufacturability through established coating processes
Solution Approach 2:
The patent utilizes a porous ceramic coating layer that maintains ion conductivity while providing thermal stability. The porous structure allows lithium ion transport similar to the underlying polymer membrane, preventing the ceramic coating from blocking ion flow. This resolves the safety improvement without excessive complexity by using a coating approach rather than completely replacing the membrane
2Temperature
If a ceramic coating is applied to the separator membrane, then high temperature performance is improved, but manufacturing complexity increases
Solution Approach 1:
The ceramic coating is applied to the separator membrane before battery assembly, allowing the coating process to be integrated into the separator manufacturing line. This preliminary action approach enables controlled application of the ceramic layer under optimized conditions, improving high temperature performance while managing manufacturing complexity through process integration
Solution Approach 2:
The patent modifies the physical and chemical parameters of the separator by adding a ceramic coating layer with specific pore size, thickness, and composition. These parameter changes enhance high temperature stability and chemical resistance while maintaining ion conductivity, resolving the contradiction by optimizing coating parameters rather than fundamentally changing the manufacturing process
3Reliability
If the separator membrane undergoes oxidation or reduction reactions, then interfacial layer formation occurs, but further reactions continue compromising safety
Solution Approach 1:
The ceramic coating layer acts as a preliminary protective barrier that prevents direct contact between the polymer membrane and electrode surfaces. This preliminary anti-action approach stops oxidation and reduction reactions at the interface before they can compromise safety, while still allowing controlled ion transport through the ceramic layer's porous structure
Solution Approach 2:
The ceramic coating serves as an intermediary layer between the polymer membrane and electrodes, mediating the interaction by providing chemical stability and preventing harmful reactions. This intermediary approach resolves the contradiction by blocking further reactions while maintaining necessary ion conductivity for battery operation
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 ceramic coated separator improves safety and cycle life by preventing further reactions and maintaining dimensional stability at elevated temperatures, with volatile component evolution above 250°C.
Implementation Method 1
The improvement in the safety, cycle life and/or high temperature performance of the coated and/or ceramic coated separator membrane is believed mainly due to the coating or ceramic coating or layer undergoing an oxidation or reduction reaction at the interface of the coated separator and electrodes in a lithium ion battery
Implementation Method 2
The improvement in the safety, cycle life and/or high temperature performance of the coated and/or ceramic coated separator membrane is believed mainly due to the coating or ceramic coating or layer undergoing an oxidation or reduction reaction at the interface of the coated separator and electrodes in a lithium ion battery
Implementation Method 3
In addition, the safety, cycle life and high temperature performance of the coated and/or ceramic coated separator membrane is improved due to its high dimensional stability at elevated temperatures
Data Source
AI summary
The present invention is directed to improved, new or modified membranes, separator membranes, or separators, and/or related methods. In accordance with at least certain embodiments, the present invention is directed to improved, new or modified nonporous, porous, or microporous battery separator membranes or separators and/or related methods of manufacture and/or use of such membranes or separators. In accordance with at least selected embodiments, the present invention is directed to improved, new or modified nonporous, porous, or microporous battery separator membranes or separators for lithium ion batteries and/or related methods of manufacture and/or use thereof. In accordance with at least selected particular embodiments, the present invention is directed to improved, new or modified nonporous, porous, or microporous battery separator membranes or separators for secondary or rechargeable lithium ion batteries and/or related methods of manufacture and/or use of such membranes or separators. In accordance with at least certain selected particular embodiments, the present invention is directed to nonporous, porous, or microporous coated porous or microporous battery separator membranes or separators for secondary lithium ion batteries and/or related methods of manufacture and/or use of such membranes or separators. In accordance with at least one embodiment, an improved, new or modified nonporous, porous, or microporous membrane, separator membrane or separator for a lithium ion battery includes a porous or microporous membrane coated with a ceramic coating or layer such as a layer of one or more particles and/or binders.