Protective coating for separators for electrochemical cells
AssigneeMoltech Corporation
InventorsQicong Ying, Steven A. Carlson, Terje A. Skotheim
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Abstract
This invention pertains to separators for electrochemical cells which comprise (i) two microporous pseudo-boehmite layers and (ii) a protective coating layer comprising a polymer interposed between the microporous pseudo-boehmite layers; electrolyte elements comprising such separators; electrical current producing cells comprising such separators; and methods of making such separators, electrolyte elements and cells.
Claims46
A method of making a separator for an electric current producing cell, said separator comprising:
- (i) at least one microporous pseudo-boehmite layer, in contact with
- (ii) at least one protective coating layer comprising a polymer;
- wherein said method comprises the steps of:
- (a) coating onto a substrate a first liquid mixture, A, comprising a boehmite sol, or alternatively, coating onto a substrate a first liquid mixture, B, comprising one or more polymers, monomers, or macromonomers, to form a first coating layer;
- (b) drying the first coating layer formed in step (a) to form said microporous pseudo-boehmite layer, if said first liquid mixture A was utilized in step (a), or alternatively, drying the first coating layer formed in step (a) to form said protective coating layer, if said first liquid mixture B was utilized in step (a), to form a dried first coating layer;
- (c) coating onto the layer formed in step (b) a second liquid mixture, B′, comprising one or more polymers, monomers, or macromonomers to form a second coating layer, if said microporous pseudo-boehmite layer was formed in step (b), or alternatively, coating onto the layer formed in step (b) a second liquid mixture, A′, comprising a boehmite sol, if said protective coating layer was formed in step (b), to form a second coating layer;
- (d) drying the second coating layer formed in step (c) to form said protective coating layer, if said second liquid mixture B′ was utilized in step (c), or alternatively, to form said microporous pseudo-boehmite layer, if said second liquid mixture A′ was utilized in step (c), to form a dried second coating layer.
A method of making a separator for an electric current producing cell, said separator comprising:
- (i) at least two microporous pseudo-boehmite layers, in contact with
- (ii) at least one protective coating layer comprising a polymer;
- wherein said method comprises the steps of:
- (a) coating onto a substrate a first liquid mixture, A, comprising a boehmite sol, to form a first coating layer;
- (b) drying the first coating layer formed in step (a) to form said microporous pseudo-boehmite layer, to form a dried first coating layer;
- (c) coating onto the layer formed in step (b) a second liquid mixture, B′, comprising one or more polymers, monomers, or macromonomers, to form a second coating layer;
- (d) drying the second coating layer formed in step (c) to form said protective coating layer, to form a dried second coating layer;
- and,
- (e) repeating steps (a) and (b) to form a third coating layer.
A separator for an electric current producing cell, wherein said separator comprises:
- (i) two microporous pseudo-boehmite layers;
- and,
- (ii) a protective coating layer comprising a polymer, interposed between said microporous pseudo-boehmite layers.
A method of making an electrolyte element for use in an electric current producing cell, wherein said electrolyte element comprises a separator comprising;
- (i) two microporous pseudo-boehmite layers;
- and (ii) a protective coating layer comprising a polymer interposed between said microporous pseudo-boehmite layers;
- wherein said method comprises the steps of:
- (a) coating onto a substrate a first liquid mixture, A, comprising a boehmite sol, to form a first coating layer;
- and,
- (b) drying the first coating layer formed in step (a) to form said microporous pseudo-boehmite layer, to form a dried first coating layer;
- (c) coating onto the layer formed in step (b) a second liquid mixture, B′, comprising one or more polymers, monomers, or macromonomers to form a second coating layer;
- (d) drying the second coating layer formed in step (c) to form said protective coating layer, to form a dried second coating layer;
- (e) repeating steps (a) and (b);
- and
- (f) contacting a surface of the structure formed in the previous step with an electrolyte, thereby causing infusion of said electrolyte into pores of said separator.
An electric current producing cell comprising a cathode, an anode and an electrolyte element interposed between said cathode and said anode, wherein said electrolyte element comprises:
- (a) a separator;
- and,
- (b) an electrolyte;
- wherein, said separator comprises:
- (i) two microporous pseudo-boehmite layers;
- and (ii) a protective coating layer comprising a polymer interposed between said two microporous pseudo-boehmite layers, and, wherein said electrolyte is contained within pores of said separator.
Dependencies are inferred from the claim text.