Low electrical resistance microporous battery separator membranes, separators, cells, batteries, and related methods
Improved microporous battery separator membranes, separators, cells, batteries including such membranes, separators, cells, and/or methods of making such membranes and/or separators, and/or methods of using such membranes and/or separators are provided. In accordance with at least certain embodiments, an improved battery separator for a secondary or rechargeable lithium battery may have low electrical resistance of less than 0.95 ohm-cm 2 , or less than 0.8 ohm-cm 2 . The inventive battery separator membrane may provide a means to achieve an improved level of battery performance in a rechargeable or secondary lithium battery based on a possibly synergistic combination of low electrical resistance, low Gurley, low tortuosity, and/or a unique trapezoid shaped pore. In accordance with at least certain multilayer embodiments (for example, a trilayer membrane made of two polypropylene layers with a polyethylene layer in between), the inventive microporous membrane or battery separator has excellent onset and rate of thermal shutdown performance.
1. A microporous membrane comprising:
a dry stretch microporous polyolefin membrane with trapezoid shaped pores, and having:
a Gurley less than 500 sec/100 cc, and
an electrical resistance less than 0.95 ohm-cm 2 .
2. The microporous membrane of claim 1 wherein the dry stretch microporous polyolefin membrane has:
a Gurley less than 150 sec/100 cc,
a tortuosity less than 1.3, and/or
said dry stretch microporous polyolefin membrane consists of a polypropylene, polyethylene, mixtures thereof, or co-polymers thereof.
3. The microporous membrane of claim 1 where said dry stretch microporous polyolefin membrane is a monolayer membrane or a multilayer membrane with a thermal shutdown function.
4. The microporous membrane of claim 1 where said dry stretch microporous polyolefin membrane is a multilayer membrane consisting of a trilayer of polypropylene/polyethylene/polypropylene.
5. The microporous membrane of claim 4 , where said trilayer of polypropylene/polyethylene/polypropylene is made by a process comprising:
extruding a polyethylene which has a melt flow index less than 1.0 g/10 minutes to form a monolayer nonporous polyethylene precursor membrane, and
extruding a polypropylene which has a melt flow index less than 1.0 g/10 minutes to form a monolayer nonporous polypropylene precursor membrane, and
laminating two plies of polypropylene precursor membrane as outer plies or layers sandwiching one inner ply or layer of polyethylene precursor membrane to form a trilayer polypropylene/polyethylene/polypropylene nonporous precursor,
machine direction stretching the trilayer polypropylene/polyethylene/polypropylene nonporous precursor membrane to form a semi-porous intermediate membrane having a puncture strength >350 gf and TD elongation >600%, and
transverse direction stretching the semi-porous intermediate membrane using a stretch ratio of 15 to 400% to form the trilayer of polypropylene/polyethylene/polypropylene which is microporous.
6. The microporous membrane of claim 5 where said stretch ratio is 25 to 100%.
7. The microporous membrane of claim 1 where said dry stretch microporous polyolefin membrane has a thickness less than 25 μm.
8. The microporous membrane of claim 1 , where said dry stretch microporous polyolefin membrane is made by a process comprising:
extruding a polypropylene which has a melt flow index less than 1.0 g/10 minutes to form a monolayer nonporous polypropylene precursor membrane, and
machine direction stretching the monolayer nonporous polypropylene precursor membrane to form a semi-porous intermediate membrane having a puncture strength >350 gf and TD elongation >600%, and
transverse direction stretching the semi-porous intermediate membrane using a stretch ratio of 15 to 400% to form the dry stretch microporous polyolefin membrane of the microporous membrane.
9. The microporous membrane of claim 8 where said stretch ratio is from 25 to 100%.
10. The microporous membrane of claim 1 , where said dry stretch microporous polyolefin membrane is a monolayer membrane.
11. The microporous membrane of claim 10 , where said dry stretch microporous polyolefin membrane is a polypropylene membrane.
12. A battery separator comprising the microporous membrane of claim 10 .
13. A battery separator comprising the microporous membrane of claim 1 .