Granted Patent B2

US 12,620,676 · App. 18/094,138 · Granted May 5, 2026

Inventors: Xingcheng Xiao (Troy, MI); Mei Cai (Bloomfield Hills, MI); Sherman H. Zeng (Troy, MI)

Assignee: GM Global Technology Operations LLC

H01M50/457H01M10/0525

Abstract

Claims (77)

1 . A coated polymer separator for a battery cell, the coated polymer separator comprising:

a polymer separator including:

a first primary surface; and

a second primary surface; and

a ceramic-based composite coating disposed on the first primary surface and the second primary surface, the ceramic-based composite coating including:

lithiated zeolite particles; and

particles of a second ceramic material including an oxide;

wherein the ceramic-based composite coating further includes, on the first primary surface:

a first layer including the lithiated zeolite particles; and

a second layer including the particles of the second ceramic material; and

wherein the ceramic-based composite coating further includes, on the second primary surface:

a third layer including the lithiated zeolite particles; and

a fourth layer including the particles of the second ceramic material.

2 . The coated polymer separator of claim 1 , wherein the ceramic-based composite coating further includes the lithiated zeolite particles mixed with the particles of the second ceramic material.

3 . The coated polymer separator of claim 1 , wherein the first layer including the lithiated zeolite particles abuts the first primary surface of the polymer separator; and

wherein the third layer including the lithiated zeolite particles abuts the second primary surface of the polymer separator.

4 . The coated polymer separator of claim 1 , wherein the second layer including the particles of the second ceramic material abuts the first primary surface of the polymer separator; and

wherein the fourth layer including the particles of the second ceramic material abuts the second primary surface of the polymer separator.

5 . The coated polymer separator of claim 1 , wherein a layer of the lithiated zeolite particles is coated upon the first primary surface of the polymer separator; and

wherein a layer of the second ceramic material is coated upon the second primary surface of the polymer separator.

6 . The coated polymer separator of claim 1 , wherein the second ceramic material is one of aluminum oxide (Al 2 O 3 ), silicon dioxide (SiO 2 ), titanium dioxide (TiO 2 ), magnesium oxide (MgO), or Boehmite (Al(OH)O)(AlHO 2 ).

7 . The coated polymer separator of claim 3 , wherein lithiated zeolite is present within the ceramic-based composite coating in a range from 20 parts by weight per 100 parts by weight of the ceramic-based composite coating to 80 parts by weight per 100 parts by weight of the ceramic-based composite coating; and

wherein the second ceramic material including an oxide may be present within the ceramic-based composite coating in a range from 20 parts by weight per 100 parts by weight of the ceramic-based composite coating to 80 parts by weight per 100 parts by weight of the ceramic-based composite coating.

8 . The coated polymer separator of claim 7 ,

wherein the coated polymer separator further includes an adhesive layer on one side or two sides;

wherein the adhesive layer is laminated to the cathode or the anode; and

wherein the adhesive layer affixes the cathode or the anode to the coated polymer separator.

9 . A battery cell including a coated polymer separator, the battery cell comprising:

an anode;

a cathode;

an electrolyte; and

the coated polymer separator, including

a polymer separator including:

a first primary surface; and

a second primary surface; and

a ceramic-based composite coating disposed on the first primary surface and the second primary surface, the ceramic-based composite coating including:

lithiated zeolite particles; and

particles of a second ceramic material including at least one oxide;

wherein the ceramic-based composite coating further includes, on the first primary surface:

a first layer including the lithiated zeolite particles; and

a second layer including the particles of the second ceramic material; and

wherein the ceramic-based composite coating further includes, on the second primary surface:

a third layer including the lithiated zeolite particles; and

a fourth layer including the particles of the second ceramic material.

10 . The battery cell of claim 9 , wherein the ceramic-based composite coating further includes the lithiated zeolite particles mixed with the particles of the second ceramic material.

11 . The battery cell of claim 9 , wherein the first layer including the lithiated zeolite particles abuts the first primary surface of the polymer separator; and

wherein the third layer including the lithiated zeolite particles abuts the second primary surface of the polymer separator.

12 . The battery cell of claim 9 , wherein the second layer including the particles of the second ceramic material abuts the first primary surface of the polymer separator; and

wherein the fourth layer including the particles of the second ceramic material abuts the second primary surface of the polymer separator.

13 . The battery cell of claim 12 , wherein the coated polymer separator further includes an adhesive layer on one side or two sides;

wherein the adhesive layer is laminated to the cathode or the anode; and

wherein the adhesive layer affixes the cathode or the anode to the coated polymer separator.

14 . The battery cell of claim 9 , wherein a layer of the lithiated zeolite particles is coated upon the first primary surface of the polymer separator; and

wherein a layer of the second ceramic material is coated upon the second primary surface of the polymer separator.

15 . The battery cell of claim 9 , wherein the second ceramic material is one of aluminum oxide (Al 2 O 3 ), silicon dioxide (SiO 2 ), titanium dioxide (TiO 2 ), magnesium oxide (MgO), or Boehmite (Al(OH)O)(AlHO 2 ).

16 . The battery cell of claim 9 , wherein lithiated zeolite is present within the ceramic-based composite coating in a range from 20 parts by weight per 100 parts by weight of the ceramic-based composite coating to 80 parts by weight per 100 parts by weight of the ceramic-based composite coating; and

wherein the second ceramic material including an oxide may be present within the ceramic-based composite coating in a range from 20 parts by weight per 100 parts by weight of the ceramic-based composite coating to 80 parts by weight per 100 parts by weight of the ceramic-based composite coating.

17 . A method to create a coated polymer separator for a battery cell including a ceramic-based composite coating, the method comprising:

applying the ceramic-based composite coating to a first primary surface of a polymer separator;

applying the ceramic-based composite coating to a second primary surface of the polymer separator; and

drying the ceramic-based composite coating; and

wherein the ceramic-based composite coating includes:

lithiated zeolite particles; and

particles of a second ceramic material including an oxide;

wherein the ceramic-based composite coating further includes, on the first primary surface:

a first layer including the lithiated zeolite particles; and

a second layer including the particles of the second ceramic material; and

wherein the ceramic-based composite coating further includes, on the second primary surface:

a third layer including the lithiated zeolite particles; and

a fourth layer including the particles of the second ceramic material.

18 . The method of claim 17 , wherein the second ceramic material is one of aluminum oxide (Al 2 O 3 ), silicon dioxide (SiO 2 ), titanium dioxide (TiO 2 ), magnesium oxide (MgO), or Boehmite (Al(OH)O)(AlHO 2 ).

19 . The method of claim 17 ,

wherein the first layer including the lithiated zeolite particles abuts the first primary surface of the polymer separator; and

wherein the third layer including the lithiated zeolite particles abuts the second primary surface of the polymer separator.

20 . The method of claim 17 ,

wherein the second layer including the particles of the second ceramic material abuts the first primary surface of the polymer separator; and

wherein the fourth layer including the particles of the second ceramic material abuts the second primary surface of the polymer separator.

Assignments (1)

Continuity (1)

References Cited (11)