Separator having porous coating layer, manufacturing method of the same, and electrochemical device having the same

A method for manufacturing a separator, comprising:

• (A) preparing a planar non-woven fabric substrate having a plurality of fibers, the fibers consist of superfine fibers, the fibers having an average thickness of 0.5 to 10 μm and having a distribution of pore sizes among which pores having a wide diameter of 0.1 to 70 μm are 50% or above of the entire pores;
• and
• (B) coating at least one surface of the non-woven fabric substrate with a binder polymer solution in which inorganic particles are dispersed, and drying the surface of the non-woven fabric substrate;
• wherein a loading weight of the inorganic particles and the binder polymer with respect to the non-woven fabric substrate is controlled in the range of 5 to 20 g/m2,
• wherein the superfine fibers have a melt temperature of 200° C. or above, and
• wherein the superfine fibers are made of any polymer selected from the group consisting of polyester, polyacetal, polycarbonate, polyimide, polyetheretherketone, polyethersulfone, polyphenylene oxide, polyphenylene sulfide, polyethylene naphthalene and mixtures thereof.

A separator comprising:

• (A) a planar non-woven fabric substrate having a plurality of fibers and pores;
• and
• (B) a porous coating layer provided on at least one surface of the non-woven fabric substrate and made of a mixture of a plurality of inorganic particles and a binder polymer,
• wherein:
• (1) the fibers of the non-woven fabric substrate consist of superfine fibers, the fibers having an average thickness of 0.5 to 10 μm;
• (2) among the distribution of pore size in the non-woven fabric substrate, pores having a wide diameter of 0.1 to 70 μm are 50% or above of the entire pores;
• and
• (3) a loading weight of the porous coating layer with respect to the non-woven fabric substrate is 5 to 20 g/m2,
• wherein the superfine fibers have a melt temperature of 200° C. or above, and
• wherein the superfine fibers are made of any polymer selected from the group consisting of polyester, polyacetal, polycarbonate, polyimide, polyetheretherketone, polyethersulfone, polyphenylene oxide, polyphenylene sulfide, polyethylene naphthalene and mixtures thereof.