Granted Patent
B2
US 12,567,651 · App. 17/861,535 · Granted Mar 3, 2026
Nanoporous composite separators with increased thermal conductivity
Inventors:
David W. Avison (Townsend, MA); Shreyans Shingi (Lowell, MA); Chandrakant C. Patel (Burlington, MA); Charles R. Comeau, Jr. (Groton, MA); Samuel Lim (Lynn, MA)
Assignee:
24M Technologies, Inc.
H01M50/446B29C41/003B29C41/02B29C71/02C08J5/22C08K3/00C09K5/08H01M10/0525H01M50/403B29K2023/00B29K2105/20B29K2709/02B29K2715/003B29L2031/3468Y02T10/70
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Abstract
Nanoporous composite separators are disclosed for use in batteries and capacitors comprising a nanoporous inorganic material and an organic polymer material. The inorganic material may comprise Al 2 O 3 , AlO(OH) or boehmite, AlN, BN, SiN, ZnO, ZrO 2 , SiO 2 , or combinations thereof. The nanoporous composite separator may have a porosity of between 35-50%. The average pore size of the nanoporous composite separator may be between 10-90 nm. The separator may be formed by coating a substrate with a dispersion including the inorganic material, organic material, and a solvent. Once dried, the coating may be removed from the substrate, thus forming the nanoporous composite separator. A nanoporous composite separator may provide increased thermal conductivity and dimensional stability at temperatures above 200° C. compared to polyolefin separators.
Claims (29)
1 . A porous composite battery separator, comprising:
a polymeric binder which comprises at least one of a polyvinylidene difluoride (PVdF) or a copolymer thereof; and
modified hydrated aluminum oxide particles dispersed in the polymeric binder, the modified hydrated aluminum oxide particles having a bimodal particle size distribution in a range from about 0.15 μm to about 0.19 μm and from about 2 μm to about 11 μm,
the porous composite battery separator having thermal conductivity of at least 0.6 W/m-K at 25° C. when measured by an ASTM E1461 method, and
the porous composite battery separator not comprising an additional polymeric separator layer.
2 . The porous composite battery separator of claim 1 which exhibits less than 1% shrinkage when exposed to a temperature of 200° C. or 220° C. for one hour.
3 . The porous composite battery separator of claim 1 , wherein the thermal conductivity of the porous composite battery separator is higher at 50° C. than at 25° C.
4 . The porous composite battery separator of claim 1 , having an average pore size from 10 nm to 50 nm.
5 . The porous composite battery separator of claim 1 , having a porosity of from 35% to 50%.
6 . The porous composite battery separator of claim 1 , wherein the PVdF has a molecular weight of equal to or greater than 1,000,000 Da.
7 . The porous composite battery separator of claim 1 , wherein the copolymer is selected from the group consisting of polyvinyl ethers, urethanes, acrylics, cellulosics, styrene-butadiene copolymers, natural rubbers, chitosan, nitrile rubbers, silicone elastomers, PEO or PEO copolymers, and polyphosphazenes.
8 . The porous composite battery separator of claim 1 , wherein a dimensional stability of the porous composite battery separator is substantially constant at temperatures from 50° C. to 250° C.
9 . The porous composite battery separator of claim 1 , wherein the modified hydrated aluminum oxide particles comprise a boehmite.
10 . An electrochemical cell comprising:
an anode;
a cathode;
an organic electrolyte comprising a lithium salt; and
a porous composite battery separator, comprising:
a polymeric binder which comprises at least one of a polyvinylidene difluoride (PVdF) or a copolymer thereof; and
modified hydrated aluminum oxide particles dispersed in the polymeric binder, the modified hydrated aluminum oxide particles having a bimodal particle size distribution in a range from about 0.15 μm to about 0.19 μm and from about 2 μm to about 11 μm,
the porous composite battery separator having a thermal conductivity of at least 0.6 W/m-K at 25° C. when measured by an ASTM E1461, and the porous composite battery separator not comprising an additional polymeric separator layer.
11 . The electrochemical cell of claim 10 which exhibits less than 1% shrinkage when exposed to a temperature of 200° C. or 220° C. for one hour.
12 . The electrochemical cell of claim 10 , wherein the thermal conductivity of the porous composite battery separator is higher at 50° C. than at 25° C.
13 . The electrochemical cell of claim 10 , having an average pore size of 10 nm to 50 nm.
14 . The electrochemical cell of claim 10 , having a porosity of 35% to 50%.
15 . The electrochemical cell of claim 10 , wherein the PVdF has a molecular weight of equal to or greater than 1,000,000 Da.
16 . The electrochemical cell of claim 10 , wherein the copolymer selected from the group consisting of polyvinyl ethers, urethanes, acrylics, cellulosics, styrene-butadiene copolymers, natural rubbers, chitosan, nitrile rubbers, silicone elastomers, PEO or PEO copolymers, and polyphosphazenes.
17 . The electrochemical cell of claim 10 , wherein a dimensional stability of the porous composite battery separator is substantially constant at temperatures from 50° C. to 250° C.
18 . The electrochemical cell of claim 10 , wherein the modified hydrated aluminum oxide particles comprise a boehmite.
Assignments (4)
ASSIGNMENT OF ASSIGNOR'S INTEREST
Recorded Sep 12, 2024
From: META MATERIALS INC.
To: 24M TECHNOLOGIES, INC.
Reel/Frame 068946/0929 →
ASSIGNMENT OF ASSIGNOR'S INTEREST
Recorded Sep 11, 2024
From: AVISON, DAVID W.; SHINGI, SHREYANS; PATEL, CHANDRAKANT C; COMEAU, CHARLES R., JR.; LIM, SAMUEL
To: MADICO, INC.
Reel/Frame 068554/0451 →
ASSIGNMENT OF ASSIGNOR'S INTEREST
Recorded Sep 11, 2024
From: MADICO, INC.
To: OPTODOT CORPORATION
Reel/Frame 068554/0463 →
ASSIGNMENT OF ASSIGNOR'S INTEREST
Recorded Oct 24, 2022
From: OPTODOT CORPORATION
To: META MATERIALS INC.
Reel/Frame 061512/0607 →
Continuity (5)
Continuation
14787426
Provisional Application
61817119
· Apr 29, 2013
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