Direct electrolyte gelling via battery separator composition and structure

• US 10,607,790 B2
• Filed: 03/15/2013
• Issued: 03/31/2020
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: DreamWeaver International, Inc.
• Original Assignee: DreamWeaver International, Inc.
• Inventors: Morin, Brian G.
• Primary Examiner(s): Cantelmo, Gregg
• Application Number:
  US13/839,740
• Publication Number:
  US 20140272599A1
• Time in Patent Office: 2,573 Days
• Field of Search: 429246, 429247, 361502
• CPC Class Codes: H01G 11/52 Separators
• CPC Class Codes: H01G 11/56 Solid electrolytes, e.g. gels; Additives therein
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/0565 Polymeric materials, e.g. gel-type or solid-type
• CPC Class Codes: H01M 10/058 Construction or manufacture
• CPC Class Codes: H01M 2300/0085 Immobilising or gelification of electrolyte
• CPC Class Codes: H01M 50/417 Polyolefins
• CPC Class Codes: H01M 50/42 Acrylic resins
• CPC Class Codes: H01M 50/44 Fibrous material
• CPC Class Codes: H01M 50/491 Porosity
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

The capability of directly gelling an electrolyte within a lithium ion (or similar type) battery cell through the reaction of the electrolyte solution with a present battery separator is provided. Such a procedure results generally from the presence of suitable nanofibers within the battery separator structure that exhibit the potential for swelling in the presence of a suitable electrolyte formulation. In this manner, the capability of providing an entrenched gel within the battery separator for longer term viability and electrical generation is possible without externally gelling the electrolyte prior to battery cell introduction. The method of use of such a resultant battery, as well as the battery including such an automatic gelling battery separator/electrolyte combination, are also encompassed within this invention.

Claims

1. A method of providing direct electrolyte gelling in a lithium ion energy storage separator, wherein said electrolyte comprises solvents, wherein said separator consists of a single layer of fabric including microfibers exhibiting a minimum width of 3000 nm and nanofibers exhibiting a maximum width of 1000 nm, wherein at least some of said nanofibers exhibit gelation upon contact with said solvents;

wherein said microfibers form a mesh and said nanofibers fill within the interstices of said microfibers;

wherein said single layer of fabric exhibits a maximum thickness of 100 micrometers;

wherein said single layer of fabric exhibits a mean flow pore size of at most 0.80 micrometers; and

wherein said microfibers exhibit an average length of less than 50 mm, said average length further being at least 5 times the average length of said nanofibers;

said method comprising the steps of;

a) providing said separator;

b) introducing said separator within a lithium ion battery;

c) contacting said separator with said electrolyte within said battery and sealing said battery; and

d) gelling said electrolyte through exposure to said at least some of said gelling nanofibers within said sealed battery.

2. The method of claim 1 wherein said nanofibers present within said single layer of fabric exhibit an average diameter of at most 700 nm.