Microporous membranes, separator membranes, base films, and uses thereof
OwnerYue Ma, Changqing Wang Adams +1inventors
InventorsYue Ma, Changqing Wang Adams, William J. Mason
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Abstract
An improved microporous membrane is described herein. The microporous membrane may be useful as a battery separator, separator membrane, base film, or membrane with a variety of uses thereof. The improved microporous membranes described herein may be dry process polyolefin membranes and may be used as battery separators or as a component of a composite or battery separator. The battery separators or composites may be used in energy storage devices including primary batteries, secondary batteries, fuel cells, capacitors, or super capacitors.
Claims20
A microporous membrane, separator membrane, battery separator, or base film comprising a microporous membrane,
- wherein the microporous membrane has a thickness from 1 microns to 50 microns, 2 microns to 25 microns, 4 microns to 12 microns, or 5 microns to 10 microns, and exhibits one or more, two or more, three or more, four or more, five or more, or all of the following properties:
- (1) a puncture strength of 230 gf or more;
- (2) an MD tensile strength above 2,200 kg/cm2;
- (3) an increased surface roughness;
- (4) an average pore size of at least 0.35 microns;
- (5) an increased DB;
- (6) a TD tensile strength above 110 kg/cm2;
- (7) a lower ply to ply adhesion force;
- (8) a polypropylene blend including up to 10% by weight long chain branched polypropylene;
- (9) a reduced surface area;
- and/or (10) a thickness of less than 12 microns.
A dry process polyolefin microporous membrane having a thickness from 4 microns to 12 microns, and exhibiting one or more of the properties:
- (1) a puncture strength of 230 gf or more;
- (2) an MD tensile strength above 2,200 kg/cm2;
- (3) an increased surface roughness;
- (4) an average pore size of at least 0.35 microns;
- (5) an increased DB;
- (6) a TD tensile strength above 110 kg/cm2;
- (7) a lower ply to ply adhesion force;
- (8) a polypropylene blend including up to 10% by weight long chain branched polypropylene;
- (9) a reduced surface area;
- and/or (10) a porosity of at least 45%.
A dry process polypropylene microporous membrane having a thickness from 4 microns to 12 microns, and exhibiting two or more of the properties:
- (1) a puncture strength of 230 gf or more;
- (2) an MD tensile strength above 2,200 kg/cm2;
- (3) an increased surface roughness;
- (4) an average pore size of at least 0.35 microns;
- (5) an increased DB;
- (6) a TD tensile strength above 110 kg/cm2;
- (7) a lower ply to ply adhesion force;
- (8) a polypropylene blend including up to 10% by weight long chain branched polypropylene;
- (9) a reduced surface area;
- and/or (10) a porosity of at least 45%.
A microporous membrane, separator membrane, battery separator, or base film comprising a microporous membrane,
- wherein the microporous membrane has a thickness from 1 microns to 50 microns, 2 microns to 25 microns, 4 microns to 12 microns, or 5 microns to 10 microns, and exhibits one or more, two or more, three or more, four or more, five or more, or all of the following properties:
- (1) a puncture strength of 130 gf or more;
- (2) an MD tensile strength above 1,000 kg/cm2;
- (3) an increased surface roughness;
- (4) an average pore size of at least 0.20 microns;
- (5) an increased DB;
- (6) a TD tensile strength above 50 kg/cm2;
- (7) a lower ply to ply adhesion force;
- (8) a polypropylene blend including up to 50% by weight long chain branched polypropylene;
- (9) a reduced surface area;
- and/or (10) a thickness of less than 32 microns.
A dry process polyolefin microporous membrane having a thickness from 3 microns to 32 microns, and exhibiting one or more of the properties:
- (1) a puncture strength of 130 gf or more;
- (2) an MD tensile strength above 1,000 kg/cm2;
- (3) an increased surface roughness;
- (4) an average pore size of at least 0.25 microns;
- (5) an increased DB;
- (6) a TD tensile strength above 50 kg/cm2;
- (7) a lower ply to ply adhesion force;
- (8) a polypropylene blend including up to 50% by weight long chain branched polypropylene;
- (9) a reduced surface area;
- and/or (10) a porosity of at least 25%.
Dependencies are inferred from the claim text.