Ceramic cross-linked coating on a porous membrane and methods for making the same

A coated battery separator comprising:

• a microporous membrane;
• and
• a cross-linked ceramic coating on at least one side of the microporous membrane, wherein the cross-linked ceramic coating comprises a surfactant, wherein the surfactant is a di-anionic surfactant, and the di-anionic surfactant has a di-carboxylate structure;
• and
• wherein the coated separator exhibits a load increase of less than 250% after 2 days in the electrolytes.

A coated battery separator comprising:

• a microporous membrane;
• and
• a cross-linked ceramic coating on at least one side of the microporous membrane, wherein the ceramic coating comprises ceramic particles, a particulate polymeric binder cross-linker or cross-linking agent, and a surfactant;
• wherein
• the ceramic particles may comprise at least one selected from the following group:
• silicon dioxide (SiO2), titanium oxide (TiO2), boehmite, aluminum oxide (Al2O3), magnesium oxide (MgO), barium sulfate (BaSO4), and calcium carbonate (CaCO3);
• the surfactant is a di-anionic surfactant, and the di-anionic surfactant has a di-carboxylate structure;
• and wherein the cross-linked ceramic coating has a thickness from 0.1 to 10 microns.

A coated battery separator comprising:

• a microporous membrane;
• and a cross-linked ceramic coating on at least one side of the microporous membrane, wherein the cross-linked ceramic coating comprises ceramic particles, a surfactant, and a polymer/polyhedral oligomer silsesquioxane (POSS) cross-linker or cross-linking agent having two or more reactive groups, wherein:
• the ceramic particles may comprise at least one selected from the following group:
• silicon dioxide (SiO2), titanium oxide (TiO2), boehmite, aluminum oxide (Al2O3), magnesium oxide (MgO), barium sulfate (BaSO4), and calcium carbonate (CaCO3);
• the surfactant is a di-anionic surfactant, and the di-anionic surfactant has a di-carboxylate structure;
• and
• wherein the cross-linked ceramic coating may have a thickness from 0.1 to 10 microns.

A coated battery separator comprising:

• a microporous membrane;
• and
• a cross-linked ceramic coating on at least one side of the microporous membrane, wherein the cross-linked coating comprises ceramic particles, a surfactant, and a polyethylene oxide (PEO)/Polyethylene glycol (PEG) cross-linker or cross-linking agent having two or more reactive groups, wherein:
• the ceramic particles may comprise at least one selected from the following group:
• silicon dioxide (SiO2), titanium oxide (TiO2), boehmite, aluminum oxide (Al2O3), magnesium oxide (MgO), barium sulfate (BaSO4), and calcium carbonate (CaCO3);
• the surfactant is a di-anionic surfactant, and the di-anionic surfactant has a di-carboxylate structure;
• and
• wherein the cross-linked coating may have a thickness from 0.1 to 10 microns.

A coated battery separator comprising:

• a porous membrane;
• and
• a cross-linked ceramic coating, comprising ceramic particles, a cross-linker or cross-linking agent, and a di-anionic surfactant having a di-carboxylate structure, wherein the di-anionic surfactant having a di-carboxylate structure has the following structure:
• wherein R3 is a C1 to C10 saturated or unsaturated branched or unbranched alkyl, alkene, or alkyne group:
• R4 is a C1 to C10 saturated or unsaturated branched or unbranched alkyl, alkene, or alkyne group;
• and R1 is an alkyne or alkene group.