Microporous Li-Ion Separator Coating for High-Temperature Electrode Isolation
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Solution Overview
Problem
Existing Lithium-ion rechargeable battery separators fail to effectively prevent contact between the anode and cathode at elevated temperatures, necessitating improved high melt temperature microporous separators that maintain structural integrity and separate electrodes for extended periods.
Innovation Solution
Development of high melt temperature microporous Lithium-ion rechargeable battery separators with a high glass transition temperature polymer coating, such as polybenzimidazole (PBI), applied via electrospinning to maintain electrode separation up to 250°C, utilizing a process that avoids immersion steps for solvent removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional polyolefin separators are used, then manufacturing is simple and cost-effective, but they fail to maintain structural integrity at elevated temperatures above 160°C
Solution Approach 1:
The patent applies composite materials by combining polyolefin base membrane with aromatic polyamide coating layers. This composite structure enables the separator to maintain structural integrity at temperatures up to 250°C while retaining manufacturing feasibility. The aromatic polyamide coating provides high-temperature stability without requiring complete redesign of the manufacturing process.
Solution Approach 2:
The patent changes the thermal parameters of the separator by introducing materials with higher glass transition temperatures and melting points. The aromatic polyamide coating raises the effective operational temperature limit from 160°C to 250°C, fundamentally altering the temperature parameter where the separator maintains its separation function.
2Reliability
If high-temperature resistant coatings are applied to separators, then electrode separation at elevated temperatures is improved, but manufacturing complexity increases due to additional immersion steps
Solution Approach 1:
The patent utilizes porous aromatic polyamide coating materials that allow solvent penetration and rapid drying. The porous structure enables the coating to be applied as a wet slurry and then dried in situ without requiring immersion steps, thereby reducing manufacturing complexity while maintaining the high-temperature separation capability.
Solution Approach 2:
The patent extracts the problematic immersion step from the manufacturing process by using coatings that can be applied and dried in situ. The aromatic polyamide coating formulation allows the solvent to evaporate during normal processing without requiring separate immersion or extraction steps, thereby simplifying the overall manufacturing process.
3Temperature
If separator coatings are applied to improve high-temperature performance, then structural integrity at elevated temperatures is enhanced, but production time increases due to additional processing steps
Solution Approach 1:
The patent applies the coating material in a pre-formulated slurry state that is optimized for rapid drying and curing. The coating is applied in advance as part of the membrane formation process, and the solvent is designed to evaporate quickly at standard processing temperatures, thereby minimizing additional production time while ensuring complete coverage and adhesion.
Solution Approach 2:
The patent employs a coating formulation and processing method that rushes through the drying and curing steps efficiently. The aromatic polyamide coating is designed to set rapidly at elevated temperatures, allowing the separator to reach operational readiness faster than conventional coatings, thereby minimizing the time penalty associated with enhanced high-temperature 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 separators effectively keep anode and cathode separated at high temperatures, allowing partial functioning and potential shutdown, with enhanced structural integrity and reduced manufacturing complexity.
Implementation Method 1
high melt temperature microporous Lithium-ion rechargeable electrospun coated battery separators
Implementation Method 2
maintain electrode separation up to 250°C, utilizing a process that avoids immersion steps for solvent removal
Data Source
AI summary
Disclosed or provided are high melt temperature microporous Lithium-ion rechargeable battery separators, shutdown high melt temperature battery separators, battery separators, membranes, composites, and the like that preferably prevent contact between the anode and cathode when the battery is maintained at elevated temperatures for a period of time, methods of making, testing and/or using such separators, membranes, composites, and the like, and/or batteries, Lithium-ion rechargeable batteries, and the like including one or more such separators, membranes, composites, and the like.