# US 10,483,513 B2 · Asymmetrical separator

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- Number: US 10,483,513 B2
- Document ID: US10483513B2
- Status: Granted
- Kind: B2
- Application number: 13/263,993
- Filed: 2010-03-29
- Published: 2012-02-02
- Granted: 2019-11-19
- Earliest claimed: 2009-04-17
- Assignees: Carl Freudenberg KG
- Applicants: Christoph Weber; Michael Roth
- Inventors: Christoph Weber; Michael Roth
- Web page: https://patentgrep.com/patent/US10483513B2

## CPC

- H01M 50/44: Fibrous material
- H01M 50/414: Synthetic resins, e.g. thermoplastics or thermosetting resins
- H01M 50/434: Ceramics
- H01M 50/451: comprising layers of only organic material and layers containing inorganic material
- H01M 50/454: comprising a non-fibrous layer and a fibrous layer superimposed on one another
- H01M 50/457: comprising three or more layers
- H01M 50/489: Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
- Y02E 60/10: Energy storage using batteries
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A separator for a battery includes a base having an anode side configured to contact an anode of the battery and a cathode side configured to contact a cathode of the battery. The anode side has a different material consistency than the cathode side.

## Claims

### Claim 1

An asymmetric separator comprising:
a base having two sides, wherein each side independently contacts an electrode of a battery, wherein the base comprises a nonwoven, wherein the base is coated on one of the two sides with a first material mixture and is coated on another of the two sides with a second material mixture,
wherein the two coated sides have a different material consistency and the first material mixture and the second material mixture at least partially penetrate into the nonwoven,
wherein the first material mixture comprises Al2O3 particles configured to set a porosity of the side coated with the first material mixture,
wherein the second material mixture comprises polyvinylidene fluoride particles having a mean particle size in a range from 0.2 μm to 10 μm and binder particles,
wherein the polyvinylidene fluoride particles are configured to set a porosity of the side coated with the second material mixture,
wherein at least a portion of the polyvinylidene fluoride particles is disposed on an outer surface of the side coated with the second material mixture so as to enable direct contact with the electrode in contact with the side coated with the second material mixture,
wherein the polyvinylidene fluoride particles are bound to the nonwoven using the binder particles,
wherein the nonwoven has a melting point higher than 140° C., and
wherein the separator has a maximum shrinkage of 5% at a temperature of 150° C.

### Claim 2 (depends on 1)

The asymmetric separator recited in claim 1, wherein the polyvinylidene fluoride particles provide a fine-porous barrier layer in contact with at least one of the two sides.

### Claim 3 (depends on 2)

The asymmetric separator recited in claim 2, wherein the fine-porous barrier layer is laminated on the base.

### Claim 4 (depends on 1)

The asymmetric separator recited in claim 1, wherein the Al2O3 particles have a mean particle size in a range from 0.2 μm to 10 μm.

### Claim 5 (depends on 1)

The asymmetric separator recited in claim 1, wherein the polyvinylidene fluoride particles have a mean particle size in a range from 0.5 μm to 4 μm.

### Claim 6 (depends on 1)

The asymmetric separator recited in claim 1, wherein at least one of the first material mixture and the second material mixture includes a substance that is swellable and configured to form a gel in an electrolyte of the battery.

### Claim 7 (depends on 1)

The asymmetric separator recited in claim 1, wherein the nonwoven is a wet-laid nonwoven that is at least one of thermally bonded and fixed by the binder.

### Claim 8 (depends on 1)

The asymmetric separator recited in claim 1, wherein the nonwoven includes fibers having a mean diameter that is no more than 5 μm.

### Claim 9 (depends on 1)

The asymmetric separator recited in claim 1, wherein the nonwoven has a melting point higher than 200° C.

### Claim 10 (depends on 1)

The asymmetric separator recited in claim 1, wherein the separator has a mean pore size in a range from 0.1 μm to 4 μm.

### Claim 11 (depends on 1)

The asymmetric separator recited in claim 1, wherein the separator has a mean pore size is in a range from 0.1 μm to 1 μm.

### Claim 12 (depends on 1)

The asymmetric separator recited in claim 1, wherein the separator has a thickness of no more than 40 μm.

### Claim 13 (depends on 12)

The asymmetric separator recited in claim 12, wherein the separator has a thickness of no more than 30 μm.