Dramatically improve the Safety Performance of Li ion Battery Separators and Reduce the Manufacturing Cost Using Ultraviolet Curing and High Precision Coating Technologies
- Miltec UV International, LLC, Stevensville, MD (United States)
The objective of this project was to improve the safety of operation of Lithium ion batteries (LIB)and at the same time significantly reduce the manufacturing cost of LIB separators. The project was very successful in demonstrating the improved performance and reduced cost attributed to using UV curable binder and high speed printing technology to place a very thin and precisely controlled ceramic layer on the surface of base separators made of polyolefins such as Polyethylene, Polypropylene and combinations of the two as well as cellulosic base separators. The underlying need for this new technology is the recently identified potential of fire in large format Lithium ion batteries used in hybrid, plug-in hybrid and electric vehicles. The primary potential cause of battery fire is thermal runaway caused by several different electrical or mechanical mechanisms; such as, overcharge, puncture, overheating, compaction, and internal short circuit. During thermal runaway, the ideal separator prevents ion flow and continues to physically separate the anode from the cathode. If the temperature of the battery gets higher, the separator may melt and partially clog the pores and help prevent ion flows but it also can shrink which can result in physical contact of the electrodes and accelerate thermal run-away even further. Ceramic coated separators eliminate many of the problems related to the usage of traditional separators. The ceramic coating provides an electrically insulating layer that retains its physical integrity at high temperature, allows for more efficient thermal heat transfer, helps reduce thermal shrinkage, and inhibits dendrite growth that could create a potential short circuit. The use of Ultraviolet (UV) chemistry to bind fine ceramic particles on separators is a unique and innovative approach primarily because of the instant curing of the UV curable binder upon exposure to UV light. This significant reduction in drying/curing time significantly reduces the cost of a ceramic coating. Another innovation is high precision, high speed, printing techniques that can apply a unique pattern of ceramic particles on base separators. The pattern will maximize ionic conductivity and minimize ceramic coating weight and thickness, while retaining the benefits of increased puncture strength, reduced thermal shrinkage and no decomposition. This project has met all of its goals and has been successfully completed. This successful completion has enabled Miltec UV to take the final steps leading to the commercialization of an innovative technology that will result in ceramic coated separators that can be manufactured and sold from the US, with increased production capacity, reduced cost, and improved battery safety.
- Research Organization:
- Miltec UV International, LLC, Stevensville, MD (United States)
- Sponsoring Organization:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE), Vehicle Technologies Office (EE-3V)
- DOE Contract Number:
- EE0006868
- OSTI ID:
- 1408277
- Report Number(s):
- DOE_MILTEC_EE-0006868
- Country of Publication:
- United States
- Language:
- English
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