Coatings, coated separators, batteries, and related methods
New and/or improved coatings for porous substrates, including battery separators or separator membranes, and/or coated porous substrates, including coated battery separators, and/or batteries or cells including such coatings or coated separators, and/or related methods including methods of manufacture and/or of use thereof are disclosed. Also, new or improved coatings for porous substrates, including battery separators, which comprise at least a polymeric binder and heat-resistant particles with or without additional additives, materials or components, and/or to new or improved coated porous substrates, including battery separators, where the coating comprises at least a polymeric binder and heat-resistant particles with or without additional additives, materials or components are disclosed. Further, new or improved coatings for porous substrates, including battery separators, and new and/or improved coated porous substrates, including battery separators, new or improved coatings for porous substrates, including battery separators, which comprise at least (i) a polymeric binder, (ii) heat-resistant particles, and (iii) at least one component selected from the group consisting of a cross-linker, a low-temperature shutdown agent, an adhesion agent, and a thickener, and new and/or improved coated porous substrates, including battery separators, where the coating comprises at least (i) a polymeric binder, (ii) heat-resistant particles, and (iii) at least one component selected from the group consisting of a cross-linker, a low-temperature shutdown agent, an adhesion agent, a thickener, a friction-reducing agent, a high-temperature shutdown agent are disclosed.
1. A coating composition comprising:
a polymeric binder comprises water as the solvent, an aqueous solvent, or a non-aqueous solvent;
heat-resistant particles; and
at least one component selected from the group consisting of a cross-linker, a low-temperature shutdown agent, an adhesion agent, a thickener, a friction reducing agent, and a high-temperature shutdown agent;
wherein the polymeric binder comprises a polylactam of Formula (1):
wherein R 1 , R 2 , R 3 , and R 4 can be alkyl or aromatic substituents and R 5 can be alkyl, aryl, or fused ring; and
wherein the polylactam can be a homopolymer or a co-polymer where co-polymeric group X can be derived from vinyl, a substituted or un-substituted alkyl vinyl, vinyl alcohol, vinyl acetate, acrylic acid, alkyl acrylate, acrylonitrile, maleic anhydride, maleic imide, styrene, polyvinylpyrrolidone (PVP), polyvinylvalerolactam, polyvinylcaprolactam (PVCap), polyamide, or polyimide;
wherein m can be an integer between 1 and 10,
and wherein the ratio of 1 to n is such that 0≤1:n≤10.
2. A coating composition comprising:
a polymeric binder comprises water as the solvent, an aqueous solvent, or a non-aqueous solvent;
heat-resistant particles; and
at least one component selected from the group consisting of a cross-linker, a low-temperature shutdown agent, an adhesion agent, a thickener, a friction reducing agent, and a high-temperature shutdown agent;
wherein the polymeric coating comprises a polylactam according to Formula (2) and a catalyst:
wherein R 1 , R 2 , R 3 , and R 4 can be alkyl or aromatic substituents;
R 5 can be alkyl, aryl, or fused ring;
m can be an integer between 1 and 10,
and wherein the ratio of 1 to n is such that 0≤1:n≤10,
and X is an epoxide or an alkyl amine.
3. The coating composition of claim 2 wherein X is an epoxide and the catalyst comprises an alkyl amine or epoxide.
4. The coating composition of claim 1 wherein the heat-resistant particles comprise an organic material or a mixture of an organic material and an inorganic material, and the organic material is at least one selected from the group consisting of: a polyimide resin, a melamine resin, a phenol resin, a polymethyl methacrylate (PMMA) resin, a polystyrene resin, a polydivinylbenzene (PDVB) resin, carbon black, and graphite.
5. The coating composition of claim 4 wherein the ratio of heat-resistant particles to binder in the coating composition is 50:50 to 99:1.
6. The coating composition of claim 4 wherein 0.01 to 99.99% of the surface area of at least one of the heat-resistant particles is coated by the binder.
7. The coating composition of claim 1 wherein the cross-linker comprising multiple reactive groups.
8. The coating composition of claim 7 wherein the cross-linker is an epoxy cross-linker comprising multiple reactive epoxy groups.
9. The coating composition of claim 7 wherein the cross-linker is an acrylate cross-linker comprises multiple reactive acrylate groups.
10. The coating composition of claim 1 wherein the low-temperature shutdown agent comprises at least one of polyethylene (PE) and polyvinyl pyrrolidone (PVP).
11. The coating composition of claim 1 wherein the adhesion agent comprises a thermoplastic fluoropolymer.
12. The coating composition of claim 1 wherein the friction reducing agent is at least one selected from a metallic stearate, a siloxane, a silicone resin, a fluororesin, a wax, and an aliphatic amide.
13. The coating composition of claim 1 wherein the high-temperature shutdown agent has a melting point of 140 to 220° C.
14. The coating composition of claim 1 wherein the high-temperature shutdown agent is selected from polyvinylpyrrolidone (PVP) or polyvinylidene difluoride (PVDF).
15. A separator comprising a porous substrate and a coating layer formed on at least one surface of the porous substrate, wherein the coating layer comprises a coating composition of claim 1 and the coating layer further comprises another different coating layer formed thereon.
16. A secondary lithium ion battery comprising the separator of claim 15 .
17. A composite comprising the separator of claim 15 in direct contact with an electrode for a secondary lithium ion battery.
18. A vehicle or device comprising the secondary lithium ion battery of claim 16 .
19. The coating composition of claim 2 wherein the heat-resistant particles comprise an organic material or a mixture of an organic material and an inorganic material, and the organic material is at least one selected from the group consisting of: a polyimide resin, a melamine resin, a phenol resin, a polymethyl methacrylate (PMMA) resin, a polystyrene resin, a polydivinylbenzene (PDVB) resin, carbon black, and graphite.
20. The coating composition of claim 19 wherein the ratio of heat-resistant particles to binder in the coating composition is 50:50 to 99:1.
21. The coating composition of claim 19 wherein 0.01 to 99.99% of the surface area of at least one of the heat-resistant particles is coated by the binder.
22. The coating composition of claim 2 wherein the cross-linker comprising multiple reactive groups.
23. The coating composition of claim 22 wherein the cross-linker is an epoxy cross-linker comprising multiple reactive epoxy groups.
24. The coating composition of claim 22 wherein the cross-linker is an acrylate cross-linker comprises multiple reactive acrylate groups.
25. The coating composition of claim 2 wherein the low-temperature shutdown agent comprises at least one of polyethylene (PE) and polyvinyl pyrrolidone (PVP).
26. The coating composition of claim 2 wherein the adhesion agent comprises a thermoplastic fluoropolymer.
27. The coating composition of claim 2 wherein the friction reducing agent is at least one selected from a metallic stearate, a siloxane, a silicone resin, a fluororesin, a wax, and an aliphatic amide.
28. The coating composition of claim 2 wherein the high-temperature shutdown agent has a melting point of 140 to 220° C.
29. The coating composition of claim 2 wherein the high-temperature shutdown agent is selected from polyvinylpyrrolidone (PVP) or polyvinylidene difluoride (PVDF).
30. A separator comprising a porous substrate and a coating layer formed on at least one surface of the porous substrate, wherein the coating layer comprises a coating composition of claim 2 and the coating layer further comprises another different coating layer formed thereon.
31. A secondary lithium ion battery comprising the separator of claim 30 .
32. A composite comprising the separator of claim 30 in direct contact with an electrode for a secondary lithium ion battery.
33. A vehicle or device comprising the secondary lithium ion battery of claim 31 .