Fluoropolymer Hybrid Composite Separator for Low-Temperature Ionic Conductivity

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Solution Overview

Problem

Lithium metal polymer (LMP) battery separators exhibit low ionic conductivity at temperatures below 80°C, making existing extrusion technologies less attractive and posing a challenge for safe and effective electrode separation.

Innovation Solution

A fluoropolymer hybrid organic/inorganic composite is processed in the molten phase using a composition comprising a pre-gel metal compound, functional fluoropolymer, and poly(alkylene oxide), which is then extruded into a dense film, incorporating electrolytic salts to enhance ionic conductivity and facilitate the manufacturing of separators for electrochemical and photo-electrochemical devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional extrusion technology is used to manufacture separators, then the manufacturing process is simple, but the ionic conductivity of the separators is low at temperatures below 80°C

Engineering Contradiction:

Improveionic conductivityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies composite materials by combining fluoropolymer with inorganic fillers (such as metal oxides or ceramic particles) to create a hybrid separator structure. This composite approach enhances ionic conductivity at lower temperatures while maintaining the benefits of extrusion manufacturing, thus resolving the contradiction between improved reliability and ease of manufacture.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical composition parameters of the separator by incorporating specific inorganic additives and adjusting the polymer matrix formulation. These parameter changes enable the separator to achieve higher ionic conductivity at temperatures below 80°C without requiring complex manufacturing processes, thereby resolving the technical contradiction.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If ionic conductivity is enhanced to improve separator performance, then the attractiveness of extrusion technologies increases, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveattractiveness of extrusion technologyVSAvoidprocessing complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-mixing the inorganic fillers with the fluoropolymer matrix before extrusion. This pre-preparation step ensures homogeneous distribution of conductive materials, enabling enhanced ionic conductivity while maintaining a relatively simple extrusion manufacturing process, thus improving productivity without significantly increasing device complexity.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If electrolytic salts are incorporated to improve ionic conductivity, then homogeneous properties are achieved, but the processing difficulty increases

Engineering Contradiction:

Improvehomogeneous propertiesVSAvoidprocessing difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the incorporation of electrolytic salts with the fluoropolymer matrix processing by integrating salt addition into the existing extrusion workflow. This combined approach ensures homogeneous distribution of electrolytic salts throughout the separator structure while minimizing additional processing steps, thereby achieving reliable homogeneous properties without significantly increasing manufacturing difficulty.

Inventive Principle:

Principle #5Merging (Combining)

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 enables the production of separators with outstanding ionic conductivity, suitable for both electrochemical and photo-electrochemical devices, improving the performance and attractiveness of extrusion technologies across a wider temperature range.

Implementation Method 1

an aqueous medium comprising at least one pre-gel metal compound (GM) obtainable by at least partial hydrolysis and/or polycondensation of at least one metal compound (M) of formula (I)

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 2

processing in molten phase the composition of the invention

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

one or more electrolytic salts may be easily incorporated and/or dispersed within the fluoropolymer hybrid organic/inorganic composite of the invention

Methodology Applied

Scientific EffectDispersion:

Data Source

PatentUS10982062B2Fluoropolymer hybrid composite

Publication Date: 2021.04.20 SYENSQO SA

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, in particular in electrochemical and in photo-electrochemical applications.