Abstract:
An electricity supply element and the ceramic separator thereof are provided. The ceramic separator is adapted to separate two electrode layers of the electricity supply element for permitting ion migration and electrical separation. The ceramic separator is made of ceramic particulates and the adhesive. The adhesive employs dual binder system, which includes linear polymer and cross-linking polymer. The adhesion and heat tolerance are enhanced by the characteristic of the two type of polymers. The respective position of the two electrode layers are maintained during high operation temperature to improve the stability, and battery performance. Also, the ceramic separator enhances the ion conductivity and reduces the possibility of the micro-short to increase practical utilization.

Description:
RELATED-APPLICATIONS 
       [0001]    This application is a continuation of the U.S. patent application Ser. No. 13/740,177, filed Jan. 12, 2013, which is continuation-in-part of U.S. patent application Ser. No. 13/323,825, filed Dec. 13, 2011, which is a continuation-in-part of U.S. patent application Ser. No. 11/755,657, filed May 30, 2007. This application claims priority to all the above-referenced applications. The claims  1  and  8  of the instant application correspond to claims 1 and 22 respectively of the parent application of Ser. No. 13/740,177. Claims 5 and 26 in the parent application of Ser. No. 13/740,177 are incorporated into claims  1  and  8  of the instant application. 
     
    
     FIELD OF INVENTION 
       [0002]    The present invention relates to an electricity supply element, in particular to an electricity supply element having a ceramic separator to enhance heat tolerance and the ion conductivity. 
       RELATED ART 
       [0003]    The separator (film) is an important unit of an lithium battery. The separator is disposed between the positive electrode layer and the negative electrode layer. The separators are used to electrically insulate the negative and positive electrode layers so that the battery electrolyte forms the only ionically conducting path therebetween. In order for the separators to provide this insulating function, the separators must exhibit a low electrical resistance, must be chemically stable in the electrolyte environment, must resist stiffening and cracking, must be wettable to the battery electrolyte, and must limit active material transport. 
         [0004]    The microporous polyolefin film, such as PE or PP, is widely used to manufacture battery separators because it is chemically stable and outstanding in physical properties. The melting point of the PE is about 130° C., and the melting point of the PP is about 160° C. Limited thermal and mechanical stability of the polymer separator may lead to overheating of the battery and explosion caused by separators melting and rupturing. Thermal operation window of separator in a battery is determined by shutdown temperature and melt down temperature. Therefore, in recent years, ceramic separators with high thermal stability and good wettability are developed. 
         [0005]    There are two types of the ceramic separator. The first type is used the ceramic particles as the main material of the separator to replace the polyolefin, such as U.S. Pat. No. 5,342,709. The second type is utilized the ceramic particles to be coated on a film made of PET, PEN or PI, such as US patent application publication no. 2008/0138700. 
         [0006]    For the first type, the ceramic particles of the separator are bonded with the electrode layer by the adhesive. The binder system of the adhesive is similar to the binder system of the electrode layers. Therefore, the solvent systems are also similar. When drying the solvent after coating, the particles rearrangement and the adhesive entanglement are occurred and the holes are produced in the bulk and at the interfaces. The holes would be a good path for ion mobility. However, due to the solvent is removed in a short time, the holes may be huge to induce micro-short. Therefore, the electrical insulation of the electrodes in battery will be compromised. 
         [0007]    For the second type, the adhesive, such as Polyvinylidene fluoride (PVDF) or PVDF-HFP, is used to bind the ceramic particles on the surface of a substrate film. Moreover, the film has holes to permit the ion migration. The ceramic particles are coated on the substrate film meant to ensure the electrical insulation of the electrodes at abnormal conditions. However, the adhesion between the PVDF or PVDF-HFP, and material of the substrate film, such as PET, PEN or PI, is weak, and the ceramic particles are easy to peel off. To increase the particle&#39;s adhesion to the substrate film, the percentage of the adhesive has to be higher. However, the ion conductivity would be lowered accordingly. 
         [0008]    Also, if the amount of the ceramic particles is raised to enhance the ion conductivity, the amount of the adhesive also has to be raised accordingly to maintain enough adhesion. Therefore, the percentage of the ceramic particles is limited, only 40% at most. The ion conductivity is limited. To increase the ion conductivity, the plasticizer or non-solvent are added into the adhesive. After the formation of the separator film, the plasticizer or non-solvent is removed to obtain holes for ion mobility to enhance the ion conductivity. 
         [0009]    Furthermore, the ceramic particles may easily absorb water, which will significantly deteriorate battery performance. To remove the absorbed water of the ceramic particles, it has to be heated at a temperature over 190° C. However, the melting point of the adhesive is not high enough. For example, the melting point of the PVDF is about 170° C., and the melting point of the PVDF-HEP is about 120-150° C. When the separator is heated at 190° C., the adhesive would melt. The distribution of the holes within the separator would be changed to worsen the electric property of the battery. Even adding the plasticizer or non-solvent as above mentioned, the holes would be refilled by the molten adhesive to lower the ion conductivity. 
         [0010]    On the other hand, if the materials of the adhesive with high heat tolerance are used, such as epoxy resin, acrylic acid resin, polyacrylonitrile (PAN), the thermal stability and the adhesion will be improved. However, these materials would form such cross-linking network with dense structure which significantly reduces ion migration and final battery performance. In other words, the distribution of the holes is not suitable for ion migration. Therefore, the ion conductivity is very low. 
         [0011]    It is noted that the reference cited in parent application of Ser. No. 13/740,177, Baba et al. (US 2010/0233547), shows that the ceramic particles mixed with a resin binder are used in the porous layer which is coated onto a porous separator substrate. Similar to the conventional technology, the ceramic particles in Baba et al. are additives for the slurry to coat onto the separator for solving certain problems. Referring to the specification of Baba et al., the PI and the derivatives thereof are exerted mainly for improving the high-temperature charge performance in the situation of keeping a large capacity and a high energy density at the same time. Although the PI and the derivatives thereof are disclosed in Baba et al., according to the specification of Baba et al., obviously the functions of the PI and the derivatives thereof are not to solve the poor ionic conductivity and/or bad electrical isolation which are all the main issues disclosed in the present invention. 
       SUMMARY OF THE INVENTION 
       [0012]    It is an objective of this invention to provide an electricity supply element and the ceramic separator thereof. The ceramic separator is made of ceramic particulates and the adhesive. The adhesive employs dual binder system, which includes linear polymer and cross-linking polymer. The adhesion and heat tolerance are enhanced by the characteristic of the two type of polymers. Therefore, the adhesive can stand at high-temperature without melting during the process of removing the absorbed water from the ceramic particulates. The ceramic separator would not be cracked and the holes, ion-migration paths, between the two electrode layers would be maintained during high operation temperature. Also, the ceramic separator enhances the ion conductivity, reduces the possibility of the micro-short and increases practical utilization. Moreover, by the dual binder system, a higher percentage of the ceramic particulates is obtained. The structure and the distribution of the holes, formed by the ceramic particulates and the dual binder system thereon, is optimized to promote a better balance between of the electrical insulation and the ionic conductivity. Therefore, the electric property of the electricity supply element is improved. 
         [0013]    It is another objective of the present invention to provide an electricity supply element and the ceramic separator thereof. The adhesive includes the linear polymer and the cross-linking polymer to be with both characteristics of adhesion and ion-migration path. A higher percentage of the ceramic particulates is obtained to improve the heat tolerance. 
         [0014]    In order to implement the abovementioned, this invention discloses an electricity supply element and the ceramic separator thereof. The electricity supply element includes a first electrode substrate, a second electrode substrate and a ceramic separator. The first electrode substrate includes a first current collector layer and a first active material layer, and the second electrode substrate includes a second current collector layer and a second active material layer. The ceramic separator is disposed between the first electrode substrate and the second electrode substrate. The ceramic separator is disposed on the first current collector layer and the second current collector layer, or disposed on the first active material layer and the second active material layer. The ceramic separator is composed of a plurality of ceramic particulates and a dual binder system thereon. The dual binder system includes a linear polymer and a cross-linking polymer. The adhesion for the ceramic particulates is improved to obtain a higher percentage of the ceramic particulates. The ceramic separator is suitable for electrical insulation and ion migration permission. Therefore, the structural strength, the ion conductivity, electrical insulation and the heat tolerance are improved and enhanced. 
         [0015]    In another embodiment, the electricity supply element includes a substrate, a first current collector layer, a first active material layer, and a second current collector layer, a second active material layer. The substrate includes a plurality of holes, which are filled with a plurality of ceramic particulates and a dual binder system thereon. The dual binder system includes a linear polymer and a cross-linking polymer. The first and the second current collector layers are deposed on the two opposite sides of the substrate and have holes according to the holes of the substrate. The active material layers are disposed on the outer side of the current collector layers respectively. Therefore, the substrate is served as a separator to permit ion migration between the first active material layer and the second active material layer. The electric charge is outputted through the current collector layers which disposed on the substrate. 
         [0016]    The ceramic separator of this invention is electrically and electrochemically inactive and composed of a plurality of ceramic particulates and a dual binder system thereon. The dual binder system includes a linear polymer and a cross-linking polymer, and the dual binder system includes about 0.01 to about 60 percent by weight of the cross-linking polymer. 
         [0017]    The cross-linking polymer may be a cross-linking polymer with network structure, such as epoxy resin, acrylic acid resin, polyacrylonitrile (PAN) or combinations thereof. The cross-linking polymer also may be a cross-linking polymer with ladder structure, such as polyimide (PI) and the derivatives thereof. 
         [0018]    Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    The present invention will become more fully understood from the detailed description given hereinbelow illustration only, and thus are not limitative of the present invention, and wherein: 
           [0020]      FIGS. 1A and 1B  illustrate the cross-sectional views of the electricity supply element of this invention. 
           [0021]      FIG. 2  illustrates the cross-sectional view of other embodiment of the electricity supply element of this invention. 
           [0022]      FIG. 3  illustrates the cross-sectional view of another embodiment of the electricity supply element of this invention. 
           [0023]      FIGS. 4A and 4B  illustrates the cross-sectional views of the electricity supply system of this invention, which further including a separator film. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0024]      FIGS. 1A and 1B  illustrate the cross-sectional views of the electricity supply element of this invention. The electricity supply element  3  includes a first electrode substrate  32 , a second electrode substrate  33  and a ceramic separator  31 . The first electrode substrate  32  includes a first current collector layer  321  and a first active material layer  322 . The first current collector layer  321  has a first surface  323  and an opposed second surface  324 . The first active material layer  322  is disposed on the first surface  323  of the first current collector layer  321 . The second electrode substrate  33  includes a second current collector layer  331  and a second active material layer  332 . The second current collector layer  331  has a first surface  333  and an opposed second surface  334 . The second active material layer  332  is disposed on the first surface  333  of the second current collector layer  331 . 
         [0025]    The ceramic separator  31  is disposed between the first electrode substrate  32  and the second electrode substrate  33 . The ceramic separator  31  may be disposed on the first active material layer  322  and the second active material layer  332 , see  FIG. 1A , or disposed on the second surface  324  of the first current collector layer  321  and the second surface  334  of the second current collector layer  331 , see  FIG. 1B . 
         [0026]    The ceramic separator  31  is composed of a plurality of ceramic particulates and a dual binder system served as an adhesive to bind thereon. The dual binder system includes a linear polymer and a cross-linking polymer. The dual binder system includes about 0.01 to about 60 percent by weight of the cross-linking polymer. The ceramic particulates include TiO 2 , Al 2 O 3 , SiO 2  with nanometer and micrometer scale, or alkylated ceramic particulates, alkaline earth metal phosphate, alkaline metal phosphate, alkaline earth metal carbonate, alkaline earth carbonate and combinations thereof. 
         [0027]    The adhesion for the ceramic particulates is improved to obtain a higher percentage of the ceramic particulates. The ceramic separator is suitable for insulation electrically and to permit ion migration. Therefore, the structural strength, the ion conductivity, electrical insulation and the heat tolerance are improved and enhanced. The linear polymer of the dual binder system may be Polyvinylidene fluoride (PVDF), polyvinylidene fluoride co-hexafluoropropylene (PVDF-HFP), Polytetrafluoroethene (PTFE), polymethylacrylate, polyacrylamide, and combinations thereof. 
         [0028]    The ceramic particulates is the main material of the ceramic separator  31 , so that the structural strength of the ceramic separator  31  is high enough to support the first electrode substrate  32  and/or the second electrode substrate  33 . The ceramic separator  31  is electrically and electrochemically inactive. Also, the ceramic separator  31  is electrical insulating to isolate electrically the first electrode substrate  32  and the second electrode substrate  33 . Furthermore, the adhesive utilizes the dual binder system, which includes the linear polymer and the cross-linking polymer. The cross-linking polymer is with higher adhesion strength. Cooperating with the linear polymer, the rigidity of the adhesive structure would not be so high as to prevent the structure to break easily. Therefore, the first electrode substrate  32  and the second electrode substrate  33  are bonded firmly to achieve the stability and safety of the electricity supply element  3 . 
         [0029]    Moreover, by the dual binder system, a higher percentage of the ceramic particulates is obtained, more than 60% or even up to 90%. The thermal stability and the heat tolerance are enhanced. Also, the structure and the distribution of the holes, formed by packing of the ceramic particulates, is optimized. And the barriers to block the ion migration are decreased due to the percentage of the adhesive is lower. Therefore, the ionic conductivity is improved. 
         [0030]    The cross-linking polymer of the dual binder system may be a cross-linking polymer with network structure, such as epoxy resin, acrylic acid resin, polyacrylonitrile (PAN) and combinations thereof. Their own network cross-linking structure is dense structure. Even cooperating with the linear polymer, the distribution of the holes is inadequate for ion migration. Also, the amount/volume of solid barriers would be increased accordingly. Therefore, the ionic conductivity of this structure is moderately less than the ionic conductivity of the conventional separator (film). However, the possibility and amount of existence of the huge holes are reduced, and the electrical insulation is improved. 
         [0031]    Therefore, the cross-linking polymer of the dual binder system may be a cross-linking polymer with ladder structure, such as polyimide (PI) and the derivatives thereof. Cooperating with the linear polymer, the distribution of the holes of the ceramic separator  31  is very well for ion migration. And the amount/volume of solid barriers would be much decreased accordingly. The distribution of the holes is even better than the separator using only linear polymer as adhesive. Therefore, the ionic conductivity of this structure is better than the ionic conductivity of the conventional separator (film). Also, the ladder cross-linking polymer, such as PI, is an electrically inactive material to promote a better balance of the electrically inactive and the ionic conductivity. 
         [0032]    On the other hand, the ceramic separator  31  is formed on the electrode layers. After curing process, the possibility of the huge holes existed at the interfaces caused by removing the solvent is reduced due to the cross-linking polymer structure. The electrical insulation is maintained and the possibility of the micro-short is reduced. Also, the cross-linking polymer structure is with high thermal stability to stand at high-temperature without melting during the process of removing the absorbed water from the ceramic particulate&#39;s surface. The cross-linking polymer structure also can stand the heat generated during charge or discharge process to maintain the respective position of the first electrode substrate  32  and the second electrode substrate  33  to improve the stability, safety, and battery performance of the electricity supply element  3 . 
         [0033]    Please refer to  FIG. 1B , to permit ion migration between the first electrode substrate  32  and the second electrode substrate  33 , the first current collector layer  321  has a plurality of holes  3213  and the second current collector layer  331  has a plurality of holes  3313 . The electrolyte impregnated into the first active material layer  322  and the second active material layer  332 . The electrolyte is a solid electrolyte, a liquid electrolyte, or a gelled electrolyte. Also, because of the wettability of the ceramic material is good, the distribution of the electrolyte is very well. 
         [0034]    As shown in  FIG. 2 , in this embodiment, the ceramic separator  31  is replaced by a substrate  20 , comparing to  FIG. 1B . The substrate  20  includes a plurality of holes  21  according to the holes  3213 ,  3313  of the first current collector layer  321  and the second current collector layer  331 . Due to the first current collector layer  321 , the substrate  20  and the second current collector layer  331  have the holes  3213 ,  21  and  3313 , the electrolyte is easier to impregnate into therein. 
         [0035]    The substrate  20  is a flexible circuit board or a rigid circuit board. As refer to  FIG. 2 , the first current collector layer  321  and the second current collector layer  331  are disposed on the substrate  20 . Therefore, a logic circuit area may be formed by extending from the substrate  20  to output electricity directly to the outside circuit/load directly. The material of the substrate  20  is insulating materials, includes polyimide (PI), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), glass fiber, and liquid crystal polymer, or the combination thereof. The substrate  20  has the holes  21  to permit ion migration. The holes  21  are formed by through holes, ant holes (non-through holes), or porous material, and filled with a plurality of ceramic particulates and a dual binder system served as an adhesive to bind thereon. The dual binder system also includes a linear polymer and a cross-linking polymer. As above-mentioned, the ionic conductivity of the electricity supply element  3  is improved. 
         [0036]    Please refer to  FIG. 3 , a separator film  41  is disposed on one side of the ceramic separator  31 . The material of the separator film  41  is insulating materials, such as polyimide (PI), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), glass fiber, and liquid crystal polymer, or the combination thereof. Also, please see  FIG. 4A , the separator film  41  extends outside the ceramic separator  31  for carry at least one electric component  42  thereon. Moreover, another ceramic separator  31 ′ may be disposed on another side of the separator film  41 , please see  FIG. 4B . 
         [0037]    In the above-mentioned embodiments of the electricity supply element  3 , any conventional package method may be used to pack. 
         [0038]    The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.