Microporous articles and methods of preparation
AssigneeSion Power Corporation
InventorSteven A. Carlson
Life of this patent
Estimating the term…
Abstract
Provided are methods of preparing an article in which a microporous layer is coated on a temporary carrier substrate and a substrate is then laminated to the microporous layer, prior to removing the temporary carrier substrate from the microporous layer. The microporous layer comprises one or more microporous xerogel layers. Optionally, the microporous layer assembly may comprise one or more non-microporous coating layers which are in contact with at least one of the microporous xerogel layers, and one of the non-microporous coating layers may be coated on the temporary carrier substrate prior to coating the microporous layer. Also provided are articles, such as electrochemical cells, capacitors, fuel cells, ink jet ink printing media, and filtration media, prepared by such methods.
Claims18
A first electrode/separator assembly comprising a microporous layer, wherein said electrode/separator assembly is prepared according to a method comprising the steps of:
- (a) coating a microporous layer on a temporary carrier substrate to form a separator assembly, wherein said microporous layer has a first surface in contact with said temporary carrier substrate and has a second surface on the side opposite from said temporary carrier substrate;
- (b) laminating said second surface of said microporous layer to a first electrode assembly to form a microporous layer/first electrode assembly;
- and
- (c) removing said temporary carrier substrate from said first surface of said microporous layer to form said first electrode/separator assembly;
- wherein said microporous layer comprises one or more microporous xerogel layers formed by drying a liquid metal oxide sol to form a xerogel layer of a solid metal oxide gel matrix with pores which are interconnected in a continuous fashion from one outermost surface of said xerogel layer through to the other outermost surface of said xerogel layer.
A separator assembly comprising a xerogel layer of a solid oxide gel matrix with pores which are interconnected in a continuous fashion from one outermost surface of said xerogel layer through to the other outermost surface of said xerogel layer, wherein said article is prepared according to a method comprising the steps of:
- (a) coating a microporous layer on a temporary carrier substrate to form a microporous layer assembly, wherein said microporous layer has a first surface in contact with said temporary carrier substrate and has a second surface on the side opposite from said temporary carrier substrate;
- (b) coating an overlying layer on said second surface of said microporous layer, wherein said overlying layer has a first surface in contact with said second surface of said microporous layer and has a second surface on the side opposite from said microporous layer;
- and
- (c) removing said temporary carrier substrate from said first surface of said microporous layer to form said separator assembly;
- wherein said microporous layer comprises one or more of said xerogel layers.
A first electrode/separator assembly comprising a xerogel layer of a solid metal oxide gel matrix with pores which are interconnected in a continuous fashion from one outermost surface of said xerogel layer through to the other outermost surface of said xero gel layer, wherein said electrode/separator assembly is prepared according to a method comprising the steps of:
- (a) coating a microporous layer on a temporary carrier substrate to form a separator assembly, wherein said microporous layer has a first surface in contact with said temporary carrier substrate and has a second surface on the side opposite from said temporary carrier substrate;
- (b) coating an overlying layer on said second surface of said microporous layer, wherein said overlying layer has a first surface in contact with said second surface of said microporous layer and has a second surface on the side opposite from said microporous layer;
- (c) laminating said second surface of said overlying layer to a first electrode assembly to form a microporous layer/first electrode assembly;
- and
- (d) removing said temporary carrier substrate from said first surface of said microporous layer to form said first electrode/separator assembly;
- wherein said microporous layer comprises one or more of said xerogel layers.
Dependencies are inferred from the claim text.