US 12,466,119 B2
Microlayer membranes, improved battery separators, and related methods
Kang Karen Xiao, Mississauga (CA); Eric J. Penegar, Fort Mill, SC (US); Takahiko Kondo, Shiga (JP); Robert Nark, Fort Mill, SC (US); Eric R. White, Fort Mill, SC (US); Xiaomin Zhang, Charlotte, NC (US); Kristoffer K. Stokes, Lunenburg, MA (US); Stefan Reinartz, Waxhaw, NC (US); and Masaaki Okada, Shiga (JP)
Assigned to Celgard, LLC, Charlotte, NC (US)
Filed by Celgard, LLC, Charlotte, NC (US)
Filed on Nov. 7, 2022, as Appl. No. 17/982,300.
Application 17/982,300 is a division of application No. 16/348,658, granted, now 11,495,865, previously published as PCT/US2017/061026, filed on Nov. 10, 2017.
Claims priority of provisional application 62/508,360, filed on May 18, 2017.
Claims priority of provisional application 62/420,781, filed on Nov. 11, 2016.
Prior Publication US 2023/0234273 A1, Jul. 27, 2023
Int. Cl. B29C 48/08 (2019.01); B29C 48/00 (2019.01); B29C 48/07 (2019.01); B29C 48/21 (2019.01); B32B 27/00 (2006.01); B32B 27/08 (2006.01); B32B 27/32 (2006.01); H01M 10/052 (2010.01); H01M 10/0525 (2010.01); H01M 50/406 (2021.01); H01M 50/417 (2021.01); H01M 50/457 (2021.01); H01M 50/489 (2021.01); H01M 50/491 (2021.01); H01M 50/494 (2021.01); H01M 50/497 (2021.01); B29K 23/00 (2006.01); B29L 31/00 (2006.01); B29L 31/34 (2006.01)
CPC B29C 48/08 (2019.02) [B29C 48/0018 (2019.02); B29C 48/0021 (2019.02); B29C 48/07 (2019.02); B29C 48/21 (2019.02); B32B 27/00 (2013.01); B32B 27/08 (2013.01); B32B 27/32 (2013.01); H01M 10/052 (2013.01); H01M 50/406 (2021.01); H01M 50/417 (2021.01); H01M 50/457 (2021.01); H01M 50/491 (2021.01); H01M 50/497 (2021.01); B29K 2023/06 (2013.01); B29K 2023/12 (2013.01); B29L 2031/3468 (2013.01); B29L 2031/755 (2013.01); B32B 2250/02 (2013.01); B32B 2250/03 (2013.01); B32B 2250/04 (2013.01); B32B 2250/05 (2013.01); B32B 2250/242 (2013.01); B32B 2264/0257 (2013.01); B32B 2270/00 (2013.01); B32B 2305/026 (2013.01); B32B 2305/30 (2013.01); B32B 2307/204 (2013.01); B32B 2307/50 (2013.01); B32B 2307/54 (2013.01); B32B 2307/70 (2013.01); B32B 2307/704 (2013.01); B32B 2307/726 (2013.01); B32B 2307/746 (2013.01); B32B 2323/04 (2013.01); B32B 2323/10 (2013.01); B32B 2457/10 (2013.01); H01M 10/0525 (2013.01); H01M 50/489 (2021.01); H01M 50/494 (2021.01); Y02E 60/10 (2013.01)] 12 Claims
OG exemplary drawing
 
1. A battery separator comprising a multilayer microporous film comprising 9 or more layers, and at least 8 or more interfaces, wherein at least three consecutive layers of the 9 or more layers each have a thickness of from 0.1 to 2 microns, and further wherein said at least three consecutive layers are coextruded and then laminated with at least one other layer to form the multilayer microporous film; wherein the multilayer microporous film comprises a first region comprising two or more layers, wherein the first region comprises polypropylene and discontinuous amorphous regions; and a second region comprising at least one layer and the multilayer microporous film having one or more of the following properties:
an average dielectric breakdown value (V) that is higher than that of a tri-layer microporous film having the same thickness, Gurley and/or porosity as the multilayer microporous film;
an average dielectric breakdown value (V) that is 1 to 35% higher than, 5 to 35% higher than, 10 to 35% higher than, 15 to 35% higher than, or 20 to 35% higher than that of a tri-layer microporous film having the same thickness, Gurley and/or porosity as the multilayer microporous film;
when measured using mercury intrusion porosimetry, exhibits a peak mercury intrusion value of log differential intrusion 5 mL/g or less, 4.5 mL/g or less, 4.0 mL/g or less, or 3.5 mL/g or less;
a MacMillan number above 5, above 5.5, above 6, above 7, above 7.5, above 8, above 9, or above 10;
a tortuosity value of 1.6 or higher, 1.7 or higher, or 2.0 or higher;
a pin removal force of less than 50 N, less than 40N, less than 30N, less than 20N, less than 15N, or less than 10N;
an electrical resistance less than or equal to 2.0, less than or equal to 1.7, less than or equal to 1.6, less than or equal to 1.5, less than or equal to 1.4, less than or equal to 1.3, less than or equal to 1.2, less than or equal to 1.1, or less than or equal to 1.0 and;
lower standard deviation value for the dielectric break down than a tri-layer microporous film having the same thickness, Gurley, and/or porosity as the multilayer microporous film.