阅读说明：本技术 具有增加的热导率的纳米多孔复合分隔物 (Nanoporous composite separators with increased thermal conductivity ) 是由 大卫·W·阿维森 莎瑞安斯·金裕 钱德拉坎特·C·帕特尔 小查尔斯·R·科莫 塞缪尔·利姆 于 2014-04-29 设计创作，主要内容包括：公开了用于电池和电容器的纳米多孔复合分隔物,所述纳米多孔复合分隔物包括纳米多孔无机材料和有机聚合物材料。无机材料可以包括Al<Sub>2</Sub>O<Sub>3</Sub>、AlO(OH)或勃姆石、AlN、BN、SiN、ZnO、ZrO<Sub>2</Sub>、SiO<Sub>2</Sub>或其组合。纳米多孔复合分隔物可以具有35％至50％或40％至45％的孔隙率。纳米多孔复合分隔物的平均孔隙尺寸可以是10nm至50nm。分隔物可以通过用包含无机材料、有机材料和溶剂的分散体涂覆基材来形成。干燥后,可以将涂层从基材移出,从而形成纳米多孔复合分隔物。纳米多孔复合分隔物可以在高于200℃的温度下提供导热性和尺寸稳定性。(Disclosed are nanoporous composite separators for batteries and capacitors comprising a nanoporous inorganic material and an organic polymeric material. The inorganic material may include Al 2 O 3 AlO (OH) or boehmite, AlN, BN, SiN, ZnO, ZrO 2 、SiO 2 Or a combination thereof. The nanoporous composite separator may have a porosity of 35% to 50% or 40% to 45%. The average pore size of the nanoporous composite separator may be 10nm to 50 nm. The separator may be formed by coating a substrate with a dispersion comprising an inorganic material, an organic material, and a solvent. After drying, the coating may be removed from the substrate, thereby forming the nanoporous composite separator. The nanoporous composite separator may provide thermal conductivity and dimensional stability at temperatures above 200 ℃.)

1. A flexible porous composite battery separator comprising:

a polymer;

a first inorganic particulate material comprising a first type of boehmite dispersed in the polymer; and

a second inorganic particulate material dispersed in the polymer, the second inorganic particulate material selected from the group consisting of silica, zirconia, and a second type of boehmite different from the first type of boehmite,

wherein the flexible porous composite battery separator exhibits a thermal conductivity greater than the thermal conductivity of a comparative separator comprising a polymeric separator layer when measured by the ASTM E1461 method.

2. The flexible porous composite battery separator of claim 1, wherein said flexible porous composite battery separator comprises no other polymeric separator layers.

3. The flexible porous composite battery separator according to claim 1, wherein the first type of boehmite differs from the second type of boehmite in composition or particle size by surface treatment.

4. The flexible porous composite battery separator of claim 1, wherein said polymer is selected from the group consisting of: polyvinylidene fluoride (PVdF) and its copolymers, polyvinyl ethers, polyurethanes, acrylics, cellulosic materials, styrene-butadiene copolymers, natural rubber, chitosan, nitrile rubber, silicone elastomers, PEO copolymers, polyphosphazenes, and combinations thereof.

5. The flexible porous composite battery separator of claim 1, wherein said flexible porous composite battery separator has a porosity of 35% to 50% and an average pore size of 10nm to 90 nm.

6. The flexible porous composite battery separator of claim 1, wherein said flexible porous composite battery separator exhibits less than 1% shrinkage when exposed to a temperature of 200 ℃ for at least one hour.

7. The flexible porous composite battery separator of claim 6, wherein said flexible porous composite battery separator exhibits less than 1% shrinkage when exposed to a temperature of 220 ℃ for at least one hour.

8. The flexible porous composite battery separator of claim 1, wherein the thermal conductivity of the flexible porous composite battery separator is higher at 50 ℃ than at 25 ℃ when measured by the ASTM E1461 method.

9. The flexible porous composite battery separator of claim 1, wherein the particles of the first inorganic particulate material and the particles of the second inorganic particulate material are grouped around the mode of the two particle size distributions.

10. The flexible porous composite battery separator of claim 1, wherein the first inorganic particulate material comprises particles of a first type of boehmite having a mode distribution centered at 100nm to 200 nm.

11. The flexible porous composite battery separator as claimed in claim 1, wherein the tensile stress of the flexible porous composite battery separator at a stretch of 2% is 1500psi or greater when measured by the method of ASTM D882-00.

12. The flexible porous composite battery separator as claimed in claim 1, wherein the tensile stress of the flexible porous composite battery separator at a stretch of 0.5% is 1000psi or greater when measured by the method of ASTM D882-00.

13. The flexible porous composite battery separator of claim 1, wherein the polymer comprises a comonomer.

14. The flexible porous composite battery separator of claim 1, wherein the first inorganic particulate material and the second inorganic particulate material comprise at least 90% boehmite by weight.

15. The flexible porous composite battery separator of claim 1, wherein the first inorganic particulate material and the second inorganic particulate material comprise at least 95% boehmite by weight.

16. The flexible porous composite battery separator of claim 1, wherein the flexible porous composite battery separator has a thermal conductivity of at least 0.6W/m-K at 25 ℃ when measured by the ASTM E1461 method.

17. The flexible porous composite battery separator of claim 1, wherein the thermal conductivity of the flexible porous composite battery separator is more than four times the thermal conductivity of a polyolefin separator of similar thickness when measured by the ASTM E1461 method.

18. An electrochemical cell, comprising:

an anode;

a cathode;

an electrolyte including a lithium salt; and

a flexible porous composite battery separator as defined in any one of claims 1 to 17.

Technical Field

The present disclosure relates generally to the field of porous membranes and to electric current producing cells and separators for use in electric current producing cells. More specifically, the present disclosure relates to porous separator membranes comprising inorganic oxides or other inorganic materials, wherein the membranes have increased thermal conductivity compared to porous separator membranes comprised of polyolefin materials. In addition, the present disclosure relates to electric current producing batteries, such as lithium ion batteries, and capacitors, comprising such porous separators having increased thermal conductivity.

Background

Lithium batteries, including rechargeable or secondary lithium ion batteries, non-rechargeable or primary lithium batteries, and other types such as lithium-sulfur batteries, are typically made by interleaving plastic separators, a metal substrate coated on both sides with a cathode layer, another plastic separator, and another metal substrate coated on both sides with an anode layer. This staggering is usually performed on complex and expensive automatic devices, in order to maintain the alignment of the strips of these materials and for other quality reasons. In addition, to obtain sufficient mechanical strength and integrity, the separator and the metal substrate are thicker, for example, 10 μm or more in thickness. For example, a typical thickness of a copper metal substrate for an anode coating is 10 μm, a typical thickness of an aluminum metal substrate for a cathode coating is 12 μm, and a plastic separator generally has a thickness of 12 μm to 20 μm. These thick separators and metal substrates are not electrochemically active and therefore reduce the volume of electroactive material in the lithium battery electrode. This limits the energy density and power density of lithium batteries.

Disclosure of Invention

One aspect of the present disclosure relates to a porous separator for a battery comprising ceramic particles and a polymer binder, wherein the porous separator has a porosity of 35% to 50% and an average pore size of 10nm to 50 nm. In some casesIn this case, the ceramic particles are selected from inorganic oxide particles and inorganic nitride particles. In some cases, the porous separator exhibits less than 1% shrinkage when exposed to a temperature of 200 ℃ for at least one hour. In some cases, the ceramic particles include Al₂O₂AlO (OH) or boehmite, AlN, BN, SiN, ZnO, ZrO₂、SiO₂And combinations thereof. In some cases, the ceramic particles comprise 65% to 95% boehmite and the balance BN. In some cases, the ceramic particles comprise 65% to 95% boehmite and a balance of AlN. In some cases, the average pore size is 10nm to 90 nm. In some cases, less than 1% of the pores have a size outside of 10nm to 90 nm. In some cases, the porosity is 35% to 50%. In some cases, the polymeric binder comprises a polymer selected from the group consisting of: polyvinylidene fluoride (PVdF) and its copolymers, polyvinyl ethers, polyurethanes, acrylics, cellulosic materials, styrene-butadiene copolymers, natural rubber, chitosan, nitrile rubber, silicone elastomers, PEO or PEO copolymers, polyphosphazenes and combinations thereof. In some cases, the porous partition has a thermal conductivity that increases when the temperature is raised from 25 ℃ to 50 ℃, the thermal conductivity being measured with one of ASTM E1461 and ASTM 1530. In some cases, the separator has a pore volume, and more than 90% of the pore volume includes pores having a pore diameter of less than 100 nm.

Another aspect of the present disclosure relates to an electrochemical cell comprising an anode, a cathode, an inorganic electrolyte comprising a lithium salt, and a porous separator layer comprising an organic polymer and a ceramic material, wherein the porous separator layer has a porosity of 35% to 50% and an average pore size of 10nm to 90nm and exhibits less than 1% shrinkage upon exposure to a temperature of 200 ℃ for at least one hour. In some cases, the inorganic ceramic particles are selected from inorganic oxide particles and inorganic nitride particles. In some cases, the inorganic ceramic particles include Al₂O₃AlO (OH) or boehmite, AlN, BN, SiN, ZnO, ZrO₂、SiO₂And combinations thereof; the organic polymer comprises PVdF and copolymer thereof, polyvinyl ether, polyurethane, acrylic resin,Cellulosic materials, styrene-butadiene copolymers, natural rubber, chitosan, nitrile rubber, silicon elastomers, PEO or PEO copolymers, polyphosphazenes, and combinations thereof. In some cases, the average pore size is 25nm to 35 nm. In some cases, the porosity is 40% to 45%.

Another aspect of the present disclosure relates to a method of making a flexible porous composite separator. The method comprises the following steps: formulating a dispersion, wherein the dispersion comprises an organic polymeric material, an inorganic ceramic material, and a solvent; applying the dispersion to a substrate to form a coating; drying and curing the coating; and removing the coating from the substrate to form a flexible porous composite separator, wherein the porous separator has a porosity of 35% to 50% and an average pore size of 10nm to 50nm and exhibits a shrinkage of less than 1% upon exposure to a temperature of 200 ℃ for at least one hour. In some cases, the average pore size is 20nm to 40nm and the porosity of the porous composite separator is 40% to 45%. In some cases, the inorganic ceramic material includes at least one of boehmite, BN, and AlN.

Another aspect of the disclosure relates to a method of transferring heat through a battery comprising increasing the temperature of an electrode in a lithium ion battery, transferring heat from the electrode to a second electrode through a separator comprising porous ceramic particles and a polymer, wherein the separator has a porosity of 35% to 50% and an average pore size of 10nm to 50 nm. In some cases, the average pore size is 20nm to 40 nm. In some cases, the separator has a plurality of pores, and each of the pores has a diameter of 10nm to 50 nm. In some cases, the separator has a plurality of pores, and none of the pores has a diameter greater than 100 nm. In some cases, the separator has a porosity of 40% to 45%. In some cases, the separator exhibits less than 1% shrinkage when exposed to a temperature of 200 ℃ for at least one hour.

Another aspect of the present disclosure relates to a flexible composite ceramic separator comprising a polymer; a first inorganic particulate material uniformly dispersed in the polymer; a second inorganic particulate material uniformly dispersed in the polymer, the second inorganic particulate material being different in size or composition from the first inorganic particulate material; and wherein the flexible composite ceramic separator exhibits a thermal conductivity greater than a thermal conductivity of a comparative composite ceramic separator of the same composition, the comparative composite ceramic separator differing from the flexible composite ceramic separator only in that the comparative composite ceramic separator comprises only a single inorganic particulate material in the same weight as the sum of the loadings of the first inorganic particulate material and the second inorganic particulate material. In some cases, the single inorganic particulate material in the comparative composite ceramic separator is the same as one of the inorganic particulate materials in the flexible composite ceramic separator.

Drawings

For the purpose of illustrating the disclosure, specific experimental data is shown in the drawings. It should be understood, however, that the disclosure is not limited to the precise data shown.

Fig. 1 to 2 show thermograms of a polymer separator and a boehmite-based separator prepared according to one embodiment of the present disclosure.

Figure 3 shows a graph comparing the thermal conductivity (measured as W/(m · K)) of a polymer separator with the thermal conductivity of a nanoporous composite separator prepared according to one embodiment of the disclosure.

Figure 4 shows a graph of thermal conductivity (measured as W/(m · K)) for a polymer separator material, a ceramic coated polymer separator material, and a nanoporous composite separator material prepared according to one embodiment of the disclosure.

Fig. 5 through 6 are graphs of dimensional stability of various separator materials, including nanoporous composite separators prepared according to one embodiment of the present disclosure.

Fig. 7 to 8 are graphs of dimensional stability of various separator materials, including nanoporous composite separators prepared according to one embodiment of the present disclosure.

Fig. 9 is a graph of differential intrusion (differential intrusion) with respect to pore size diameter of a polymeric separator material and a nanoporous composite separator material prepared according to one embodiment of the disclosure.

Figure 10 is a graph of tensile stress versus percent stretch for two separator materials, including a nanoporous composite separator material prepared according to one embodiment of the present disclosure.

Fig. 11 is a graph of particle size distributions of various boehmite and Boron Nitride (BN) mixtures according to various embodiments of the present disclosure.

Fig. 12 is a graph of particle size distributions of various boehmite and aluminum nitride (AlN) mixtures according to various embodiments of the present disclosure.

Fig. 13 is a graph of viscosity curves for various boehmite and Boron Nitride (BN) mixtures in liquid form, according to various embodiments of the present disclosure.

Fig. 14 is a flow chart illustrating a process for preparing a nanoporous composite separator according to one embodiment of the invention.

Detailed Description

Disclosed are nanoporous composite separators comprising a porous/nanoporous inorganic material and an organic polymeric material. Such composite separators may be used, for example, in batteries and/or capacitors. The inorganic material may include Al₂O₃AlO (OH) or boehmite, AlN, BN, SiN, ZnO, ZrO₂、SiO₂Or a combination thereof. The organic polymeric material may include, for example, polyvinylidene fluoride (PVdF) and its copolymers, polyvinyl ethers, polyurethanes, acrylics, cellulosic materials, styrene-butadiene copolymers, natural rubber, chitosan, nitrile rubber, silicone elastomers, polyethylene oxide (PEO) or PEO copolymers, polyphosphazenes, or combinations thereof. In one embodiment, the flexible nanoporous composite separator has a porosity of 35% to 50% or 40% to 45% and an average pore size of 10nm to 50 nm. The separator may be formed by coating a substrate with a dispersion comprising an inorganic material, an organic material, and a solvent. After drying, the coating may be removed from the substrate, thereby forming the nanoporous composite separator. The nanoporous composite separator may provide thermal conductivity and dimensional stability at temperatures above 200 ℃.

General overview

The porous separator plays an important role in cell design, including preventing physical contact between the anode and cathode, while facilitating ionic transport of the electrochemical energy supply as needed. Large lithium ion batteries can operate at average temperatures ranging from 20 ℃ to 70 ℃; however, the peak of the battery charge and/or discharge may contribute to the short term temperature of the battery exceeding 110 ℃. Separators for lithium ion batteries are typically polyolefin separators, such as polypropylene or polyethylene, which may shrink and/or melt at such high temperatures due to chemical decomposition and the like. Although these plastic separators have low electrical conductivity required to isolate the battery electrodes from each other, the plastic separators also have very low thermal conductivity, and thus slow or inefficient heat dissipation within the battery. As lithium ion batteries are increasingly used in high capacity applications, such as electric vehicles and/or hybrid vehicles, the need to improve safety has increased substantially due to the large size and high power ratio of these battery packs. In some cases, it may be desirable for the battery separator to maintain dimensional stability (i.e., shrinkage of the separator material less than 5.0%) at temperatures of 200 ℃ or higher to ensure battery performance and safety. Coating a polyolefin separator with a ceramic-based material and/or selecting a higher melting temperature polymer-based material (PET, polyamide, PVdF, etc.) may increase thermal stability/battery failure temperature to some extent; however, these techniques add cost and do not address the underlying divider design issue: rapid, efficient and uniform heat transfer throughout the cell.

Thus, according to one embodiment of the present disclosure, a nanoporous inorganic separator material that is electrically insulating, thermally conductive, and maintains dimensional stability at temperatures above 200 ℃. In one embodiment, the nanoporous separator layer comprises an inorganic material (also referred to as a ceramic material and/or a ceramic filler material) and an organic polymer that acts as a binder to bind the inorganic material together. The nanoporous composite separator exhibits a balance of mechanical strength, ionic conductivity, thermal conductivity, and electrical insulation, making it suitable as a separator membrane for an electrochemical cell. Suitable inorganic ceramic materials may include, for example, high thermal conductivity ceramic particles, such as Al₂O₃AlO (OH) or BMum stone, AlN, BN, SiN, ZnO, ZrO₂、SiO₂And combinations of the foregoing materials. In some embodiments, the nanoporous composite separator may be formed by dispersing one or more of these inorganic materials in organic or inorganic polymeric materials, including but not limited to: PVdF and/or copolymers thereof, polyvinyl ethers, polyurethanes, acrylics, cellulosic materials, styrene-butadiene copolymers, natural rubber, chitosan, nitrile rubber, silicone elastomers, PEO or PEO copolymers, polyphosphazenes, and combinations thereof.

Table 1 provides some suitable exemplary inorganic ceramic materials suitable for forming the nanoporous composite separators disclosed herein. Inorganic materials are listed along with their corresponding thermal and electrical properties.

TABLE 1

In some embodiments, the thermal conductivity of hexagonal boron nitride (h-BN) may be 600 or 30 depending on its orientation. In addition to the inorganic materials shown in table 1, the inorganic materials may also include boehmite or a combination of any of these materials. Boehmite is a hydrated form of alumina that can be stable up to temperatures in excess of 600 ℃. The crystal structure of boehmite is octahedral and arranged in a wavy layer, and thus is less prone to moisture absorption than other alumina-based materials. In some embodiments, various properties of the nanoporous composite separator may be tuned by tuning, for example, particle size, organic polymer, particle size distribution, porosity of the inorganic material, specific surface area of the nanoporous material, and/or surface treatment. In some embodiments, the particle size distribution of the composite separator may be tailored by mixing boehmite with various other inorganic materials in various ratios. For example, the nanoporous spacer material may be pure boehmite (with less than 1% impurities), may be 90% boehmite with 10% BN or AlN, or it may be 70% boehmite with 30% BN or AlN. Various other ratios and combinations of these inorganic materials are evident in light of this disclosure, and this disclosure is not intended to be limited to any particular combination or ratio of inorganic materials. In some embodiments, the nanoporous composite separator comprises inorganic particles and an organic polymer binding the inorganic particles together to form a uniform separator.

In one specific example, a nanoporous composite separator was prepared by mixing a 4:1 by weight mixture of boehmite pigment and PVdF polymer with a dispersant in an organic solvent mixture comprising N-methylpyrrolidone (NMP) and 2-butanone, and coating the mixture onto a silicon release film. In other embodiments, the solvent may include other suitable solvents or combinations of solvents, such as benzene, ethylbenzene, toluene, xylene, MEK, NMP, or 2-butanone. After oven drying and subsequent delamination from the release film, a porous boehmite-based separator having a thickness of 20 μm was obtained. The porosity of the separator was about 42%, and the separator exhibited less than 1% shrinkage when heated in an oven at 220 ℃ for 1 hour. In another embodiment, the nanoporous composite separator exhibits a shrinkage of less than 0.5% under similar heating conditions.

In another embodiment, the organic polymer material may be a high molecular weight PVdF, such asSolef 5130 PVdF. The particular organic material may provide strong adhesion to the current collector, and in a particular example, the nanoporous composite separator comprises 4.5 parts by weight boehmite per 1 part by weight Solef 5130. In other embodiments, the introduction of a small amount of comonomer may increase the adhesive strength of the spacer material. In some embodiments, decreasing the ratio of inorganic oxide to organic polymer decreases the porosity and cycle rate performance of the separator material while increasing its mechanical strength.

In another embodiment, the nanoporous composite separator may have a porosity of 35% to 50%, a uniform distribution of pores throughout the separator material, and/or an average pore size of 20nm to 40 nm. In various embodiments, the separator has a porosity of 40% to 45%. In other embodiments, the inorganic material may not comprise pores greater than 100nm, 90nm, 80nm, 70nm, 60nm, 50nm, or 40 nm. In other embodiments, less than 1% or less than 0.1% of the pores are greater than 100nm, 90nm, 80nm, 70nm, 60nm, 50nm, or 40 nm. In other embodiments, the average pore size is 10nm to 50nm, 20nm to 40nm, or 25nm to 35 nm. In other embodiments, more than 99% or 99.9% of the pores in the composite separator are from 10nm to 90nm, from 10nm to 50nm, from 20nm to 40nm, or from 25nm to 35 nm. The nanoporous composite separator may exhibit similar properties in the machine direction (along the length of the sample) and the cross direction (along the width of the sample) if the separator material is not oriented during processing.

Many lithium batteries for automotive use are designed to be flat or ribbed, as compared to cylindrical metal batteries commonly used in lithium batteries for portable computers and other applications. In some cases, manufacturing a high energy and economical lithium battery for automotive or other applications may include: increasing the proportion or percentage of electroactive material in each battery, and reducing the complexity and expense of automated equipment used to manufacture the batteries. In some embodiments, lithium batteries can increase the content of electroactive materials by using thinner separators and/or metal substrate layers. Such lithium batteries can be manufactured, for example, on automated processing equipment that is less complex and less expensive than, for example, spooling equipment for portable computer batteries. In some embodiments, automated processing equipment may be particularly suitable for manufacturing flat or ribbed batteries.

In one embodiment, a dispersion can be prepared that includes an inorganic material, a polymeric material, and a solvent in a desired ratio. The dispersion may then be coated onto a temporary carrier substrate and allowed to dry and/or cure to achieve the desired mechanical properties before removal from the substrate. After drying and/or curing, the composite material may be removed from the substrate (or the substrate may be removed from the composite material), thereby forming the nanoporous composite separator. In various embodiments, the porous separator layer may be a film having a thickness of 5 μm to 50 μm, 10 μm to 30 μm, 7 μm to 20 μm, 10 μm to 20 μm, or 2015 μm to 25 μm.

Nanoporous composite separator embodiments

Fig. 1 to 2 show thermograms of a polymer separator generated with an infrared camera (FLIR Model 8300) and a boehmite-based separator prepared according to one embodiment of the present disclosure. Fig. 1 is a thermogram of a polyethylene separator film after exposure to a heated stainless steel substrate, and fig. 2 is a thermogram of a boehmite-based separator film of similar thickness after exposure to a heated stainless steel substrate in a similar manner. The bright spots 101 in fig. 1 correspond to areas of increased thermal concentration, while the dark spots 103 correspond to areas of decreased thermal concentration. The uniform heat distribution observed in the boehmite-based separator in fig. 2 is evident compared to the non-uniform heat distribution seen in plastic separators.

Figure 3 shows a graph comparing the thermal conductivity (measured as W/(m · K)) of a polymer separator with the thermal conductivity of a nanoporous composite separator prepared according to one embodiment of the disclosure. The measurements in FIG. 3 were according to ASTM E1461 fromLFA-447 from Instruments, Burlington, MA was performed with a laser flash (transient) method. These measurements demonstrate the higher thermal conductivity of the nanoporous composite separator compared to typical polyolefin separator materials. Columns 301 and 303 depict the thermal conductivity of the nanoporous composite separator exposed to 25 ℃ and 50 ℃, respectively, while column 305 and column 307 depict the thermal conductivity of the polyolefin separator material exposed to 25 ℃ and 50 ℃, respectively. In this embodiment, the polyolefin separator material used is 18 μm thickThree layers, and the nanoporous composite separator has a thickness of 21 μm and comprises boehmite (Boehmite) in a ratio of 4.5:110SR) andsolef 5130. As can be seen in fig. 3, the thermal conductivity of the nanoporous composite separator is four times higher than the thermal conductivity of a polyolefin separator of similar thickness. In some embodiments, the enhanced thermal conductivity further increases as the temperature increases from 25 ℃ to 50 ℃. This property of increasing thermal conductivity with increasing temperature is particularly useful for the safety of lithium ion batteries, since the heat generated during operation of the batteries causes them to typically operate at temperatures of about 50 ℃. Spreading the heat in the cell quickly and uniformly is critical to minimize local heat buildup to avoid any "hot spots" or other non-uniform heated areas.

Figure 4 shows a graph of thermal conductivity (measured as W/(m · K)) for a polymeric separator material, a ceramic coated polymeric separator material, and a nanoporous composite separator prepared according to one embodiment of the disclosure. The thermal conductivities depicted in fig. 4 were measured according to the ASTM E1530 protected hotplate (steady state) method with an estimated deviation of ± 3.0%. These measurements demonstrate the higher thermal conductivity of the nanoporous composite separator compared to typical polyolefin separator materials and ceramic coated polymer separator materials. In this particular example, the sample measured comprised two separator materials measured in fig. 3, and was prepared by coating 18 μm thick with a 3.5 μm layer comprising boehmite and polymeric binder material in a 5.5:1 ratioThird sample prepared on each side of the three layers. Column 401 and column 403 depict the thermal conductivity of the nanoporous composite separator measured at 25 ℃ and 50 ℃, respectively; columns 405 and 407 depict the thermal conductivity of the polyolefin separator material measured at 25 ℃ and 50 ℃, respectively; column 409 and column 411 depict the thermal conductivity of the ceramic coated polymer spacer material measured at 25 ℃ and 50 ℃, respectively. In this particular embodiment, the thermal conductivity of the nanoporous composite separator is about twice that of a polyolefin separator material of similar thickness, while the ceramic coated separator material exhibits heat relative to the polyolefin separator material in terms of thermal conductivityA slight improvement of about 20% in conductivity.

Fig. 5 through 6 are graphs of dimensional stability of various separator materials including a nanoporous composite separator prepared according to one embodiment of the present disclosure. Figure 5 shows the dimensional change (measured in μm) of various spacer materials as a function of temperature measured along the length of the sample, while figure 6 shows the dimensional change measured along the width of the material sample. In the examples shown in fig. 5 to 6, 501 shows the dimensional change of the polymer separator material, 503 shows the dimensional change of the ceramic coated polymer separator material on one side, 505 shows the dimensional change of the ceramic coated polymer separator material on both sides, and 507 shows the dimensional change of the nanoporous composite separator prepared according to an embodiment of the present disclosure. In this particular example, the polymer separator corresponding to plot 501 is 18 μm thick with a Gurley air permeability of 300 seconds/100 ccThree layers of polyolefin. The separator corresponding to plot 503 was coated on one side with boehmite (b) comprising a ratio of 5.5:110SR) and Arkema761 and a separator has a Gurley gas permeability of 470 seconds/100 cc. The separator corresponding to plot 505 was coated on both sides with boehmite (b) comprising a ratio of 5.5:110SR) and Arkema761 and a separator has a Gurley air permeability of 600 seconds/100 cc. The nanoporous composite separator corresponding to plot 507 comprises boehmite (boehmite) (1) in a ratio of 4.5:110SR) andsolef 5130, 21 μm thick, having a Gurley permeability of 900 seconds/100 cc and a porosity of 40%. As can be seen in fig. 5 to 6, the dimensional stability of the polymer separator 501 and the ceramic coated polymer separators 503-505 varies greatly from 100 ℃ to 170 ℃, while the nanoporous composite separator 507 maintains high dimensional stability well above 200 ℃.

Fig. 7 through 8 are graphs of dimensional stability (measured as percent shrinkage) of various separator materials including a nanoporous composite separator prepared according to one embodiment of the disclosure. Figure 7 shows the percent shrinkage of various spacer materials as a function of temperature measured along the length of the sample, while figure 8 shows the percent shrinkage measured along the width of various material samples. The percent shrinkage shown in fig. 7-8 is measured in one hour without limitation according to ASTM 1204 standard test method for measuring linear dimensional change. In the illustrated example, 701 shows the percent shrinkage of the polymer separator material, 703 shows the percent shrinkage of the ceramic coated polymer separator material on one side, 705 shows the percent shrinkage of the ceramic coated polymer separator material on both sides, and 707 shows the percent shrinkage of the nanoporous composite separator prepared according to an embodiment of the disclosure. In this particular embodiment, the various partitions corresponding to the illustrations 701, 703, 705, and 707 are the same partitions described above with reference to the illustrations 501, 503, 505, and 507, respectively. As can be seen in fig. 7 to 8, the shrinkage percentage of the polymer spacer material 701 and the first ceramic coated polymer spacer 703 increases substantially at temperatures above 100 ℃. The second ceramic-coated polymer separator material 705 experienced a smaller magnitude increase in the percent shrinkage, while the nanoporous composite separator material 707 was maintained at a percent shrinkage of 0.5% or less at temperatures above 160 ℃.

Figure 9 is a graph of pore size diameter (measured in μm) relative to a polymeric separator material and a nanoporous flexible composite separator prepared according to one embodiment of the disclosureAmount) of differential intrusion (measured in mL/g). In this particular embodiment, 901 shows a porosity of about 40% and comprises boehmite (boehmite) in a ratio of 4.5:110SR) anddifferential intrusion of a 20 μm thick nanoporous composite separator of Solef 5130; 903 shows a thickness of 18 μmDifferential intrusion of the three-layer polymer spacer material. As can be seen in this embodiment, the pore size distribution 901 corresponding to the nanoporous composite separator is centered at about 30nm and has a smaller average size compared to the distribution 903 corresponding to the polymer separator. In some embodiments, such narrow pore size distribution and small average size may minimize the risk of dendrite penetration of the separator, which may lead to local shorts. In other embodiments, the pore size distribution of the nanoporous composite separator may be concentrated in 10nm to 90nm, 10nm to 50nm, 20nm to 40nm, or 25nm to 35 nm. In some embodiments, the pore size may be adjusted by formulation parameters of the nanoporous composite separator. As discussed above, reducing the ratio of inorganic oxide to organic polymer reduces the porosity and cycling rate performance of the material while increasing the mechanical strength of the material.

Figure 10 is a graph of tensile stress (measured in psi) versus percent stretch for two separator materials comprising a nanoporous composite separator prepared according to one embodiment of the disclosure. In this example, 1001 shows 18 μm thickTensile stress of the three-layer polymer separator material, while 1003 shows a porosity of about 40% and comprises boehmite (boehmite) in a ratio of 4.5:110SR) andtensile stress of a 20 μm thick nanoporous composite separator of Solef 5130. In this particular embodiment, the dividers corresponding to illustrations 1001 and 1003 are the same dividers described above with reference to illustrations 501, 503, 505, and 507, respectively. The target tensile stress for the american advanced battery Consortium (USABC) is 1000psi and is shown by line 1005. The tensile stress illustrated in fig. 10 is measured along the length of a material sample using the ASTM D882-00 standard method for measuring tensile properties of thin plastic sheets. In another embodiment, the compressive strength of the nanoporous composite separator 1003 is greater than twice the compressive strength of the polymer separator material 1001.

Fig. 11 is a graph of particle size distribution (volume percent relative to particle size in μm) of various boehmite and Boron Nitride (BN) mixtures according to various embodiments of the present disclosure. In a particular embodiment, the BN used isCarbotherm PCTP 05. As can be seen in this example, according to three embodiments of the present disclosure, 1101 plots the particle size distribution for 100% boehmite material, 1103 plots the particle size distribution for a composition comprising 90% boehmite and 10% BN, 1105 plots the particle size distribution for a composition comprising 70% boehmite and 30% BN. The mode of the boehmite material distribution 1101 is about 0.1 μm. In this particular example, the boehmite material distribution 1101 comprises a single mode, while the 90% boehmite composition 1103 and the 70% boehmite composition 1105 each show a bimodal distribution with modes of 0.15 μm to 0.19 μm and 2 μm to 3 μm.

Fig. 12 is a graph of particle size distribution (volume percent relative to particle size in μm) of various boehmite and aluminum nitride (AlN) mixtures according to various embodiments of the present disclosure. As can be seen in this example, according to three embodiments of the present disclosure, 1201 depicts the particle size distribution of a separator material comprising 100% boehmite, 1203 depicts the particle size distribution of a separator material comprising 90% boehmite and 10% BN, and 1205 depicts the particle size distribution of a separator material comprising 70% boehmite and 30% BN. In one embodiment, the mode of the boehmite material distribution 1201 is about 0.1 μm, similar to the mode of the boehmite material distribution 1101 shown in fig. 11. In this particular embodiment, boehmite material distribution 1201 comprises a single mode, while 90% boehmite material 1203 and 70% boehmite material 1205 each exhibit a bimodal distribution. The mode of the 90% boehmite material distribution 1203 is about 0.15 μm to 0.19 μm and about 8 μm to 11 μm, while the mode of the 70% boehmite material distribution 1205 is 0.12 μm to 0.18 μm and about 7 μm to 10 μm.

In some embodiments, the inorganic particles may have different sizes grouped around two, three, or four modes. It is believed that by using a multimodal distribution of differently sized particles, the particles may be encapsulated in the separator in a manner that provides increased heat transfer and better compressive strength while maintaining or even improving the porosity of the separator. Particles grouped around different modes may have the same or different compositions. For example, boehmite particles having a mode distribution centered at about 100nm can be combined with additional boehmite particles having a mode distribution centered at about 2 μm. In other embodiments, boehmite particles having a mode distribution centered at about 100nm may be combined with additional AlN or BN particles having a mode distribution centered at about 2 μm. The ratio of the particle size of the first mode to the particle size of the second mode may be, for example, greater than 1:2, 1:3, 1:5, or 1: 10. In other embodiments, the ratio of the particle sizes of the two modes may be, for example, less than 1:100, 1:50, 1:20, 1:10, 1:5, or 1: 3. The ratio of the amount of the two different sized particles used in the separator (weight/weight) may be greater than 1:1, 2:1, 5:1, or 10: 1.

Fig. 13 is a graph of viscosity curves (viscosity in cPs measured relative to shaft rotation speed in rpm) for various boehmite and Boron Nitride (BN) mixtures in liquid form according to various embodiments of the present disclosure. As can be seen in this example, according to three embodiments of the present disclosure, 1301 depicts the viscosity curve for a 100% boehmite material, 1303 depicts the viscosity curve for a composition comprising 90% boehmite and 10% BN, 1305 depicts the viscosity curve for a composition comprising 70% boehmite and 30% BN.

In some embodiments, the BN-modified compositions 1103-1105 and 1303-1305 may have a thermal conductivity higher than that of pure boehmite compositions due to the bimodal particle size distribution that enables dense packing of the mixed filler. Also, in other embodiments, the AlN-modified composition 1203-1205 may have a thermal conductivity higher than that of the pure boehmite composition due to the bimodal particle size distribution of the AlN-modified composition.

Fig. 14 is a flow chart illustrating a process for preparing a nanoporous composite separator according to one embodiment of the invention. The method may first mix 1401 the inorganic particles with a solvent. In some embodiments, the inorganic particles may include Al₂O₃AlO (OH) or boehmite, AlN, BN, SiN, ZnO, ZrO₂、SiO₂Or a combination thereof, and the solvent may include toluene, xylene, MEK, NMP, 2-butanone, or any other suitable solvent or combination thereof. The method may then add polymeric binder material 1402 to form a dispersion. In some embodiments, the polymeric binder material may include polyvinylidene fluoride (PVdF) and its copolymers, polyvinyl ethers, polyurethanes, acrylics, cellulosic materials, styrene-butadiene copolymers, natural rubber, chitosan, nitrile rubber, silicon elastomers, PEO or PEO copolymers, polyphosphazenes, or combinations thereof. The process may then coat 1403 the dispersion onto the substrate and dry/cure the dispersion to form the nanoporous composite partition 1404. After drying, the process may then proceed from the substrate nanoporous composite partition 1405.

Although the present disclosure has been described in detail and with reference to specific and general embodiments thereof, various changes and modifications will be apparent to those skilled in the art without departing from the spirit and scope of the present disclosure.