Process of manufacturing porous separator for electrochemical power supply
OwnerFrank M. Delnickinventor
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Abstract
A method of forming a porous composite separator layer for an electrochemical cell comprising the steps of printing a thin layer of a separator precursor solution on the surface of one of the electrochemical cell electrodes, curing the thin layer of separator precursor solution so that it transforms into a microporous composite separator structure. In the preferred embodiment, the separator precursor solution is formulated as an ink comprising a silica aerogel filler material dispersed in a solution of polymer binder which is dissolved in a suitable solvent. The process allows the manufacture of thin and flexible composite separators which are conformally bonded to the underlying electrodes.
Claims32
A process for fabricating a composite separator layer having electrolyte fillable voids for an electrochemical cell which includes an electrode, comprising the steps of:
- disposing a solution of separator precursor on said electrode wherein said solution comprises a solid particulate material and a polymer binder, the weight ratio of said binder to said solid particulate material is selected between 5/95 and 50/50;
- and
- transforming said solution of separator precursor so that voids from between particles of said solid particulate material.
A process for fabricating a porous composite separator for an electrochemical cell which includes an electrode, comprising the steps of:
- disposing a solution of separator precursor on said electrode wherein said solution comprises 60% to 95% by mass of 1,2,3,4-Tetrahydronaphthalene (THN) solvent;
- and
- curing said solution of separator precursor so that said solution of separator precursor forms a porous composite separator that adheres to said electrode.
A process of forming a separator layer having electrolyte fillable voids for an electrochemical cell which includes an electrode, comprising:
- printing a continuous layer of said separator on said electrode by disposing a solution comprised of a solid particulate material, a binder for said solid particulate material and a solvent to dissolve said binder wherein the weight ratio of said binder to said solid particulate material is selected between 5/95 and 50/50;
- and
- curing said layer to form interconnected empty interstices between particles of said solid particulate material therein.
A process of forming a separator layer having electrolyte fillable voids for an electrochemical cell which includes an electrode, comprising:
- conformally bonding a continuous layer of said separator on said electrode by disposing a solution comprised of a solid particulate material, a polymer binder for said solid particulate material and 60% to 95% by mass 1,2,3,4-Tetrahydronaphthalene (THN) solvent to dissolve said polymer binder wherein the weight ratio of said polymer binder to said solid particulate material is selected between 5/95 and 50/50;
- and
- curing said layer to form micropores therein.
A process for fabricating a separator layer having electrolyte fillable voids for an electrochemical cell, comprising:
- providing a sheet of solid particles separated by interconnected voids;
- and
- binding said solid particles together without filling said voids.
A process for fabricating a separator layer having electrolyte fillable voids for an electrochemical cell, comprising:
- providing an electrode;
- and
- forming a continuous layer of solid particulate material and solvent on said electrode;
- and
- removing said solvent from said layer.
A process for fabricating a separator layer having electrolyte fillable voids for an electrochemical cell, comprising:
- providing an electrode;
- and
- forming a non-self-supporting separator layer of insulating material having said voids on said electrode.
Dependencies are inferred from the claim text.