Celgard Inc.

Brian R Stepp

Kang Karen Xiao

Changqing Wang Adams

Eric Robert White

Stefan Reinartz

Katharine R Chemelewski

Masaaki Okada

Xiaomin Zhang

Kristoffer K Stokes

Daniel R Alexander

Shante P Williams

William John Mason

Barry J Summey

Robert Moran

Jeffrey Gordon Poley

Andrew Edward Voss

Douglas George Robertson

Allen M Donn

Yao Lu

Robert A Nark

Eric Joseph Penegar

Takahiko Kondo

Hisaki Ikebata

A new or improved microporous monolayer, bilayer, trilayer, or multilayer membrane, separator membrane, separator, or coated separator is disclosed. The membrane is preferably made up of at least one resin or polymer and at least one additive. The additive may comprise at least one material that improves adhesion of the microporous membrane to a coating, including a polyaramid-containing coating and a PCS coating, or to a different material such as a metallic surface, including an electrode surface. Improvements in adhesion are based on comparisons to similar microporous membranes without the at least one additive. In some preferred embodiments, the at least one additive may comprise, consist of, or consist essentially of a functionalized polymer or the combination of a functionalized polymer and an elastomer. In some embodiments, the functional group of the functionalized polymer may be maleic anhydride (MAH). Also disclosed is a battery separator or coated separator comprising the new or improved microporous membrane. The battery separator may comprise the microporous membrane coated with a polyaramid-containing coating. Also disclosed is a new or improved separator, composite, battery, secondary lithium ion battery, and/or vehicle or device comprising the separator, composite, or battery.

Battery separators, coated battery separators, batteries, and related methods

Novel or improved microporous single or multilayer battery separator membranes, separators, batteries including such membranes or separators, methods of making such membranes, separators, and/or batteries, and/or methods of using such membranes, separators and/or batteries are provided. In accordance with at least certain embodiments, a multilayer dry process polyethylene/polypropylene/polyethylene microporous separator which is manufactured using the inventive process which includes machine direction stretching followed by transverse direction stretching and a subsequent calendering step as a means to reduce the thickness of the multilayer microporous membrane, to reduce the percent porosity of the multilayer microporous membrane in a controlled manner and/or to improve transverse direction tensile strength. In a very particular embodiment, the inventive process produces a thin multilayer microporous membrane that is easily coated with polymeric-ceramic coatings, has excellent mechanical strength properties due to its polypropylene layer or layers and a thermal shutdown function due to its polyethylene layer or layers. The ratio of the thickness of the polypropylene and polyethylene layers in the inventive multilayer microporous membrane can be tailored to balance mechanical strength and thermal shutdown properties.

Membranes, calendered microporous membranes, battery separators, and related methods

Described herein is a multilayer microporous film or membrane that may exhibit improved properties, including improved dielectric break down and strength, compared to prior monolayer or tri-layer microporous membranes of the same thickness. The preferred multilayer microporous membrane comprises microlayers and one or more lamination interfaces or barriers. Also disclosed is a battery separator or battery comprising one or more of the multilayer microporous films or membranes. The inventive battery and battery separator is preferably safer and more robust than batteries and battery separators using prior monolayer and tri-layer microporous membranes. Also, described herein is a method for making the multilayer microporous separators, membranes or films described herein.

Microlayer membranes, battery separators, batteries, and related methods

Described herein, are battery separators, comprising the following: a microporous polymeric film; and an optional coating layer on at least one side of the microporous polymeric film, wherein at least one of the microporous polymeric film and the optional coating comprises an additive. The additive is selected from the group consisting of a lubricating agent, a plasticizing agent, a nucleating agent, a shrinkage reducing agent, a surfactant, an SEI improving agent, a cathode protection agent, a flame retardant additive, LiPFsalt stabilizer, an overcharge protector, an aluminum corrosion inhibitor, a lithium deposition agent or improver, or a solvation enhancer, an aluminum corrosion inhibitor, a wetting agent, and a viscosity improver. Also, described herein are batteries, including lithium-ion batteries, comprising one or more of the described separators. Methods for making the battery separators are also described.

Additives for improved battery performance, improved additive-containing membranes, improved battery separators, improved batteries, and related methods

Growing community of inventors

Scottsdale, AZ, United States of America

Brian R Stepp