Coated separator and one-step method for preparing the same
In a one-step method for preparing a coated separator, a suspension of i) a ceramic, ii) a cermet, iii) a ceramic with an electrolyte, or iv) a cermet with an electrolyte in a carrier liquid is plasma sprayed without a carrier gas. The carrier liquid is water, alcohol, ethylene glycol, or mixtures thereof.
1. A one-step method for preparing a coated separator, the one step method comprising:
plasma spraying, without a carrier gas, a suspension of i) a ceramic with an electrolyte, or ii) a cermet with an electrolyte, in a carrier liquid of water, alcohol, ethylene glycol, or mixtures thereof, the suspension including a monomer selected from the group consisting of methyl methacrylate, acrylonitrile, vinyl chloride, and polyethylene glycol diacrylate.
2. The one-step method as defined in claim 1 wherein the suspension further includes a metal-organic precursor in isopropanol.
3. The one-step method as defined in claim 1 wherein the suspension further includes a polymeric complex.
4. The one-step method as defined in claim 1 wherein the suspension is introduced as a liquid stream into plasma jet used in the plasma spraying.
5. The one-step method as defined in claim 1 wherein the suspension is nebulized into droplets and then introduced into plasma jet used in the plasma spraying.
6. The one-step method as defined in claim 1 wherein the suspension further includes a dispersant.
7. The one-step method as defined in claim 1 wherein the plasma spraying is performed at a temperature less than or equal to 150° C.
8. The one-step method as defined in claim 1 wherein:
the suspension of i) the ceramic with the electrolyte includes a ceramic material and the electrolyte; or
the suspension of ii) the ceramic with the electrolyte includes a ceramic material, a metallic material, and the electrolyte.
9. The one-step method as defined in claim 8 wherein the plasma spraying forms a coating on a porous membrane, and wherein the method further comprises controlling a temperature of the plasma spraying to control a melting state of the ceramic material or the ceramic material and the metallic material.
10. The one-step method as defined in claim 9 wherein the ceramic material is at least partially melted, or the ceramic material and the metallic material are at least partially melted.
11. The one-step method as defined in claim 1 wherein the plasma spraying forms a coating on a porous membrane and wherein the carrier liquid in the suspension causes a cooling effect during plasma spraying, whereby a bond strength between the coating and the porous membrane is increased.
12. The one-step method as defined in claim 1 wherein the carrier liquid is water and wherein no external cooling mechanism is used in the one-step method.
13. The one-step method as defined in claim 1 wherein the plasma spraying forms a coating on a porous membrane and wherein the method further comprises adjusting a parameter of the plasma spraying to control a thickness of the coating such that the thickness ranges from about 0.1 μm to about 250 μm.
14. The one-step method as defined in claim 1 wherein the plasma spraying forms a coating on a porous membrane and wherein the method further comprises adjusting a parameter of the plasma spraying to control a porosity of the coating.