Process of manufacturing porous separator for electrochemical power supply
First Claim
1. 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.
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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.
153 Citations
32 Claims
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1. A process for fabricating a composite separator layer having electrolyte fillable voids for an electrochemical cell which includes an electrode, comprising the steps of:
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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. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A process for fabricating a porous composite separator for an electrochemical cell which includes an electrode, comprising the steps of:
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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. - View Dependent Claims (9, 10)
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11. A process of forming a separator layer having electrolyte fillable voids for an electrochemical cell which includes an electrode, comprising:
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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. - View Dependent Claims (12, 13, 14, 15)
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16. A process of forming a separator layer having electrolyte fillable voids for an electrochemical cell which includes an electrode, comprising:
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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. - View Dependent Claims (17, 18, 19, 20)
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21. A process for fabricating a separator layer having electrolyte fillable voids for an electrochemical cell, comprising:
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providing a sheet of solid particles separated by interconnected voids; and binding said solid particles together without filling said voids. - View Dependent Claims (22, 23, 24, 25)
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26. A process for fabricating a separator layer having electrolyte fillable voids for an electrochemical cell, comprising:
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providing an electrode; and forming a continuous layer of solid particulate material and solvent on said electrode; and removing said solvent from said layer. - View Dependent Claims (27, 28, 29)
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30. A process for fabricating a separator layer having electrolyte fillable voids for an electrochemical cell, comprising:
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providing an electrode; and forming a non-self-supporting separator layer of insulating material having said voids on said electrode. - View Dependent Claims (31, 32)
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Specification