Fluoropolymer Hybrid Composite Films for Low-Temperature Battery Separators
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Solution Overview
Problem
Lithium metal polymer batteries face a challenge with low ionic conductivity of separators at temperatures below 80°C, making existing extrusion technologies less attractive and unsafe for electrode separation.
Innovation Solution
A process for manufacturing a fluoropolymer hybrid organic/inorganic composite is developed, involving a pre-composite formed by partial hydrolysis and polycondensation of metal compounds with fluoropolymers, combined with poly(alkylene oxide) and metal salts, processed in a molten phase using extrusion techniques to create dense films with enhanced ionic conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If film extrusion technology is used to manufacture separators, then manufacturing process is simple and attractive, but ionic conductivity of separators is low at temperatures below 80°C
Solution Approach 1:
The patent applies composite materials by combining fluoropolymer with inorganic fillers (such as metal oxides, metal fluorides, or ceramic particles) to create a hybrid separator material. This composite structure enables the separator to maintain both processability through extrusion and high ionic conductivity at low temperatures, resolving the contradiction between manufacturing simplicity and functional performance.
Solution Approach 2:
The patent modifies the chemical composition parameters of the separator by incorporating specific inorganic additives and adjusting the fluoropolymer structure. These parameter changes enhance the ionic conductivity of the separator material itself, allowing it to achieve high performance at lower temperatures while remaining compatible with standard extrusion manufacturing processes.
2Reliability
If separator ionic conductivity is enhanced to improve performance below 80°C, then reliability improves, but manufacturing complexity increases making extrusion less attractive
Solution Approach 1:
The patent achieves enhanced ionic conductivity by modifying material composition parameters rather than changing the manufacturing process itself. By adjusting the types and amounts of inorganic fillers and fluoropolymer ratios, high performance is obtained while maintaining compatibility with simple extrusion processing, thus avoiding increased manufacturing complexity.
Solution Approach 2:
The patent introduces inorganic fillers with specific local properties (high ionic conductivity, thermal stability) into the fluoropolymer matrix. These locally enhanced regions provide the necessary ionic conductivity without requiring complex overall structural changes or additional manufacturing steps, maintaining process simplicity while improving performance.
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 resulting composite films exhibit outstanding ionic conductivity, suitable for use in electrochemical and photo-electrochemical devices, particularly as separators in lithium-ion batteries, improving performance and safety across a broader temperature range.
Implementation Method 1
at least partial hydrolysis and/or polycondensation, in the presence of a liquid medium, of at least one metal compound [compound (M)]
Implementation Method 2
at least partial hydrolysis and/or polycondensation, in the presence of a liquid medium, of at least one metal compound
Implementation Method 3
processing in molten phase, preferably extruding the composition provided in step (ii)
Data Source
AI summary
The present invention pertains to a fluoropolymer hybrid organic/inorganic composite, to a film comprising said fluoropolymer hybrid organic/inorganic composite and to uses of said film in various applications, especially in electrochemical and in photo-electrochemical applications.