Patent FR725560A successfully refreshed from Google Patents.
EP0814520A2
Expired / Lapsed
EP
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Process of manufacturing porous separator for electrochemical power supply
Assignee: IMRA America Inc
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Filing: 1997-06-02
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Granted: —
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Expires: 2017-06-02
Abstract
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, drying and 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.
Inventors
- 👤 Frank M. Dr. Delnick
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-10-28 01:22
CPC Classifications
H; H01; H01G; H01G9/00; H01G9/004; H01G9/02; H01M; H01M10/00; H01M10/04; H01M10/0436; C; C25; C25B; C25B9/00; C25B9/17; C25B9/19; C25B9/23; H01M50/00; H01M50/40; H01M50/403; H01M50/409; H01M50/411; H01M50/414; H01M50/426; H01M50/431; H01M50/434; H01M50/46; H01M50/489; H01M6/00; H01M6/14; H01M6/16; Y; Y02; Y02E; Y02E60/00; Y02E60/10; Y02P; Y02P70/00; Y02P70/50
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
53 words
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; and transforming said solution of separator precursor so that said solution of separator precursor forms a porous composite separator that adheres to said electrode.
Claim 2
Dependent Claim
44 words
The process of Claim 1, wherein the step of disposing a solution of separator precursor on said electrode comprises disposing a solution comprised of a solid particulate material, a polymer binder for said solid particulate material and a solvent to dissolve said polymer binder.
Claim 3
Dependent Claim
28 words
The process of Claim 2, wherein said solution of separator precursor comprises a ratio of said polymer binder to said solid particulate material of between 5/95 and 35/65.
Claim 4
Dependent Claim
20 words
The process of Claim 2, wherein said solution of separator precursor contains 60% to 75% by mass of said solvent.
Claim 5
Dependent Claim
49 words
The process of Claim 2, wherein said solid particulate material comprises a material selected from the group consisting of silica aerogel, fumed silica, silica gel, silica hydrogel, silica xerogel, silica sol, colloidal silica, alumina, titania, magnesia, kaolin, talc, diatomaceous earth, calcium silicate, calcium carbonate, magnesium carbonate, and mixtures thereof.
Claim 6
Dependent Claim
28 words
The process of Claim 2, wherein said polymer binder comprises a material selected from the group consisting of polyvinyl chloride, polyvinylidene fluoride-hexafluoropropylene copolymer and ethylene propylene hexadiene monomer.
Claim 7
Dependent Claim
13 words
The process of Claim 2, wherein said solvent comprises 2(2-Butoxy Ethoxy) Ethyl Acetate.
Claim 8
Dependent Claim
32 words
The process of Claim 1, wherein said step of disposing a solution of separator precursor on said electrode comprises using a printing technique to dispose said solution of precursor on said electrode.
Claim 9
Dependent Claim
47 words
The process of Claim 1, wherein said step of transforming said solution of separator precursor on said electrode comprises: first drying said solution of separator precursor to form a layer of separator material; and subsequently curing said layer of separator material to form a porous separator layer.
Claim 10
Dependent Claim
42 words
The process of Claim 9, wherein said step of drying comprises applying heat to said solution of separator precursor in a vacuum oven at a temperature of about 90-130°C so that said solution of separator precursor forms said layer of separator material.
Claim 11
Dependent Claim
44 words
The process of Claim 9, wherein said step of curing comprises applying heat to said separator precursor in an convection oven at a temperature of about 190°C to 240°C so that said layer of separator material transforms into said layer of porous composite separator.
Claim 12
Dependent Claim
21 words
The process of Claim 11, wherein said porous composite separator layer has a thickness in the range of 5µ to 100µ.
Claim 13
Dependent Claim
93 words
An electrochemical cell comprising: a first layer of electrode material; a layer of porous composite separator material disposed on said first layer of electrode material, wherein said composite material defines a plurality of micropores and wherein said layer of porous composite material adheres to said first layer of electrode material; a second layer of electrode material superjacent to said porous composite layer; and a liquid electrolyte contained within said plurality of pores of said porous composite separator material so that said electrolyte provides a conducting medium between said first and second electrode layers.
Claim 14
Dependent Claim
33 words
The electrochemical cell of Claim 13, wherein said first and said second electrode layers comprise a material selected from the group consisting of oxides, sulfides, carbon compounds, metals, alloys, intermetallics, and mixtures thereof.
Claim 15
Dependent Claim
55 words
The electrochemical cell of Claim 13, wherein said porous composite separator layer comprises a composite structure comprised of a solid particulate material and a polymer binder to hold said particulate material wherein the proportion of said binder to said solid particulate material is selected to permit said liquid electrolyte to permeate through said composite structure.
Claim 16
Dependent Claim
29 words
The electrochemical cell of Claim 15, wherein said porous composite separator layer comprises a ratio of said polymer binder to said solid particulate material of between 5/95 and 35/65.
Claim 17
Dependent Claim
49 words
The electrochemical cell of Claim 15, wherein said particulate material comprises a material selected from the group consisting of silica aerogel, fumed silica, silica gel, silica hydrogel, silica xerogel, silica sol, colloidal silica, alumina, titania, magnesia, kaolin, talc, diatomaceous earth, calcium silicate, calcium carbonate, magnesium carbonate, and mixtures thereof.
Claim 18
Dependent Claim
29 words
The electrochemical cell of Claim 15, wherein said polymer binder comprises a material selected from the group consisting of polyvinyl chloride, polyvinylidene fluoride-hexafluoropropylene copolymer and ethylene propylene hexadiene monomer.
Claim 19
Dependent Claim
52 words
The electrochemical cell of Claim 15, wherein said porous composite separator layer is formed by combining said solid particulate material, said polymer binder and a solvent into a solution which is disposed on said first electrode layer and is then transformed into said porous composite separator layer through the application of heat.
Claim 20
Dependent Claim
56 words
An electrochemical cell having a liquid-electrolyte-permeable separator, comprising: an electrode; a layer of solid particulate material relying on said electrode for mechanical support; and a binder for said solid particulate material, the proportion of said binder to said solid particulate material being selected to permit liquid electrolyte to permeate throughout said layer of solid particulate material.
Claim 21
Dependent Claim
49 words
The electrochemical cell of Claim 20, wherein said particulate material comprises a material selected from the group consisting of silica aerogel, fumed silica, silica gel, silica hydrogel, silica xerogel, silica sol, colloidal silica, alumina, titania, magnesia, kaolin, talc, diatomaceous earth, calcium silicate, calcium carbonate, magnesium carbonate, and mixtures thereof.
Claim 22
Dependent Claim
28 words
The electrochemical cell of Claim 20, wherein said binder comprises a material selected from the group consisting of polyvinyl chloride, polyvinylidene fluoride-hexafluoropropylene copolymer and ethylene propylene hexadiene monomer.
Claim 23
Dependent Claim
29 words
The electrochemical cell of Claim 20, wherein said porous composite separator layer comprises a ratio of said polymer binder to said solid particulate material of between 5/95 and 35/65.
Claim 24
Dependent Claim
34 words
A process of forming a microporous separator for an electrochemical cell which includes an electrode, comprising: printing a continuous layer of said separator on said electrode; and drying said layer to form micropores therein.
Claim 25
Dependent Claim
32 words
The process of Claim 24, wherein said step of drying comprises applying heat to said continuous layer of separator on said electrode in a vacuum oven at a temperature of about 90-130°C.
Claim 26
Dependent Claim
33 words
The process of Claim 24, further comprising curing said continuous layer of said separator by applying heat to said separator precursor in a convection oven at a temperature of about 190°C to 240°C.
Claim 27
Dependent Claim
29 words
The process of Claim 24, wherein said step of printing said continuous layer of said separator on said electrode comprises using either a stencil or a screen printing technique.
Claim 28
Dependent Claim
48 words
The process of Claim 24, wherein said step of printing said continuous layer of said separator on said electrode comprises disposing a solution comprised of a solid particulate material, a polymer binder for said solid particulate material and a solvent to dissolve said polymer binder on said electrode.
Claim 29
Dependent Claim
60 words
An electrochemical cell having a liquid-electrolyte-permeable separator, comprising an electrode: a matrix of solid particulate material which is so thin that it would not be self supporting, which matrix is supported directly on said electrode; and sufficient binder to hold said solid particulate material in an open matrix which permits liquid electrolyte to permeate said layer of solid particulate material.
Claim 30
Dependent Claim
49 words
The electrochemical cell of Claim 29, wherein said particulate material comprises a material selected from the group consisting of silica aerogel, filmed silica, silica gel, silica hydrogel, silica xerogel, silica sol, colloidal silica, alumina, titania, magnesia, kaolin, talc, diatomaceous earth, calcium silicate, calcium carbonate, magnesium carbonate, and mixtures thereof.
Claim 31
Dependent Claim
28 words
The electrochemical cell of Claim 29, wherein said binder comprises a material selected from the group consisting of polyvinyl chloride, polyvinylidene fluoride-hexafluoropropylene copolymer and ethylene propylene hexadiene monomer.
Claim 32
Dependent Claim
28 words
The electrochemical cell of Claim 29, wherein said liquid-electrolyte-permeable separator layer comprises a ratio of said polymer binder to said solid particulate material of between 5/95 and 35/65.
Claim 33
Dependent Claim
35 words
A process of forming a microporous separator for an electrochemical cell which includes an electrode, comprising: conformally bonding a continuous layer of said separator on said electrode; and drying said layer to form micropores therein.
Claim 34
Dependent Claim
46 words
The process of Claim 33, wherein the step of conformally bonding said continuous layer of said separator on said electrode comprises disposing a solution comprised of a solid particulate material, a polymer binder for said solid particulate material and a solvent to dissolve said polymer binder.
Claim 35
Dependent Claim
26 words
The process of 34, wherein said step of disposing said solution on said electrode comprises using a printing technique to dispose said solution on said electrode.
Claim 36
Dependent Claim
31 words
An electrochemical cell, comprising: an electrode; a discontinuous frangible layer of silica particles having voids therebetween supported directly on said electrode; and a fluid organic solution electrolyte contained within said voids.
Claim 37
Dependent Claim
52 words
The electrochemical cell of Claim 36, wherein said discontinuous layer of silica particles on said electrode comprises a polymer binder to hold said silica particles wherein the proportion of said binder to said silica particles is selected to permit said fluid organic solution electrolyte to permeate through voids in said discontinuous layer.
Claim 38
Dependent Claim
29 words
The electrochemical cell of Claim 36, wherein said discontinuous layer of silica particles comprises a ratio of said polymer binder to said silicate particles of between 5/95 and 35/65.
Claim 39
Dependent Claim
29 words
The electrochemical cell of Claim 38, wherein said polymer binder comprises a material selected from the group consisting of polyvinyl chloride, polyvinylidene fluoride-hexafluoropropylene copolymer and ethylene propylene hexadiene monomer.
Claim 40
Dependent Claim
71 words
An electrochemical cell, comprising: an electrode; a discontinuous frangible layer of solid particles having voids therebetween adjacent said electrode; and a fluid organic solution electrolyte contained within said voids, wherein the ratio of the specific resistivity of the electrolyte to the specific resistivity of the electrolyte filled separator is greater than 0.10, using a complex impedance measurement over the frequency range of 100,000Hz to 0.01Hz and a sinusoidal voltage of 5mV.
References Cited (Backward Citations)
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