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 Lithium battery with secondary battery separator

Details
Inventors: Ma, Jackson C.; Megahed, El-Sayed; Stachoviak, Timothy J.; Craanen, Shirley A.; Schneider, Daniel A.; Nestler, Joseph P.;
Assignee:
Primary Examiner: Maples; John S.
Assistant Examiner:
Attorney, Agent or Firm: Michael Best & Friedrich LLP, Frenchick, Esq.; Grady J., Yager, Esq.; Charlene L.

A secondary battery separator comprises a fibrous core coated with a polymer having improved electrode adhesion properties in unitary laminated construction. Vacuum removal of plasticizer without solvent extraction prevents brittleness and results in microporosity in a thin layer of enhanced ion conductivity.

DETAILED DESCRIPTION In accordance with the present invention, a separator suitable for use in a secondary lithium battery is made of a pre-formed porous non-woven mat comprising a first homopolymer of polypropylene, polyethylene, or polyvinylalcohol, coated with a second homopolymer.
Porosity of the homopolymeric coating, which may preferably be polyvinylidene difluoride, is obtained by first mixing the homopolymer with a low boiling solvent selected from one or more non-aromatic aliphatic diesters, followed by forming a layer of the polymer diester mixture.
The resultant separator, positionable between anode and cathode electrodes, comprises a porous core layer matrix, the layer having opposite surfaces, and at least one of the surfaces having a porous homopolymeric coating applied thereto.
Then remove the solvent plasticizer by applying a vacuum.
The separator construct is sufficiently permeable to electrolyte ions to minimally discharge a secondary battery having a carbonaceous or other lithium intercalation anode and a lithium metal oxide cathode, 30 percent at 2 C.
In use, the separator is a component of a rechargeable lithium battery comprising a housing, preferably sealed in plastic, electrodes contained in the housing including a carbonaceous or other lithium intercalation anode consisting of amorphous graphite, coke, filamentous carbon, or combinations thereof, and a lithium metal oxide cathode, an electrolyte solution in the housing, the electrolyte solution containing a lithium metal salt capable of ionizing in an organic solvent, the salt being dispersed in the organic solvent, current collectors electrically connected and disposed in contact with the electrodes, and the separator disposed between the electrodes, the separator including a fibrous matrix core having surfaces, and a porous hombpolymeric coating layer applied to at least one of the matrix core surfaces.
In the process of manufacturing the separator, a fibrous polymeric core matrix is coated with a second polymer mixture containing a non-aromatic solvent plasticizer of low boiling temperature, and acetone, and then removing the plasticizer by heating under vacuum, to create a microporous layer conductive to lithium salt ions



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