CA2305271A1 - Lithium ion polymer cell separator - Google Patents
Lithium ion polymer cell separator Download PDFInfo
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- CA2305271A1 CA2305271A1 CA002305271A CA2305271A CA2305271A1 CA 2305271 A1 CA2305271 A1 CA 2305271A1 CA 002305271 A CA002305271 A CA 002305271A CA 2305271 A CA2305271 A CA 2305271A CA 2305271 A1 CA2305271 A1 CA 2305271A1
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- Prior art keywords
- separator
- cell
- cathode
- anode
- polymer
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 229910001416 lithium ion Inorganic materials 0.000 title claims abstract description 12
- 229920000642 polymer Polymers 0.000 title claims description 23
- HBBGRARXTFLTSG-UHFFFAOYSA-N Lithium ion Chemical compound [Li+] HBBGRARXTFLTSG-UHFFFAOYSA-N 0.000 title claims description 11
- 239000000463 material Substances 0.000 claims description 20
- -1 polypropylene Polymers 0.000 claims description 9
- 239000004743 Polypropylene Substances 0.000 claims description 4
- 239000004750 melt-blown nonwoven Substances 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 239000011521 glass Substances 0.000 claims description 3
- 239000003365 glass fiber Substances 0.000 claims description 2
- 230000002687 intercalation Effects 0.000 claims description 2
- 238000009830 intercalation Methods 0.000 claims description 2
- 239000011248 coating agent Substances 0.000 claims 2
- 238000000576 coating method Methods 0.000 claims 2
- 239000003575 carbonaceous material Substances 0.000 claims 1
- 239000000758 substrate Substances 0.000 abstract description 10
- 239000000835 fiber Substances 0.000 abstract description 2
- 210000004027 cell Anatomy 0.000 description 45
- 239000003792 electrolyte Substances 0.000 description 10
- 239000012528 membrane Substances 0.000 description 7
- 239000000203 mixture Substances 0.000 description 6
- 238000010276 construction Methods 0.000 description 5
- 238000003475 lamination Methods 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 5
- DHKHKXVYLBGOIT-UHFFFAOYSA-N 1,1-Diethoxyethane Chemical compound CCOC(C)OCC DHKHKXVYLBGOIT-UHFFFAOYSA-N 0.000 description 4
- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- TZIHFWKZFHZASV-UHFFFAOYSA-N methyl formate Chemical compound COC=O TZIHFWKZFHZASV-UHFFFAOYSA-N 0.000 description 4
- XTHFKEDIFFGKHM-UHFFFAOYSA-N Dimethoxyethane Chemical compound COCCOC XTHFKEDIFFGKHM-UHFFFAOYSA-N 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- RUOJZAUFBMNUDX-UHFFFAOYSA-N propylene carbonate Chemical compound CC1COC(=O)O1 RUOJZAUFBMNUDX-UHFFFAOYSA-N 0.000 description 3
- WNXJIVFYUVYPPR-UHFFFAOYSA-N 1,3-dioxolane Chemical compound C1COCO1 WNXJIVFYUVYPPR-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- OIFBSDVPJOWBCH-UHFFFAOYSA-N Diethyl carbonate Chemical compound CCOC(=O)OCC OIFBSDVPJOWBCH-UHFFFAOYSA-N 0.000 description 2
- NIQCNGHVCWTJSM-UHFFFAOYSA-N Dimethyl phthalate Chemical compound COC(=O)C1=CC=CC=C1C(=O)OC NIQCNGHVCWTJSM-UHFFFAOYSA-N 0.000 description 2
- 101150058243 Lipf gene Proteins 0.000 description 2
- DOIRQSBPFJWKBE-UHFFFAOYSA-N dibutyl phthalate Chemical compound CCCCOC(=O)C1=CC=CC=C1C(=O)OCCCC DOIRQSBPFJWKBE-UHFFFAOYSA-N 0.000 description 2
- FLKPEMZONWLCSK-UHFFFAOYSA-N diethyl phthalate Chemical compound CCOC(=O)C1=CC=CC=C1C(=O)OCC FLKPEMZONWLCSK-UHFFFAOYSA-N 0.000 description 2
- JBTWLSYIZRCDFO-UHFFFAOYSA-N ethyl methyl carbonate Chemical compound CCOC(=O)OC JBTWLSYIZRCDFO-UHFFFAOYSA-N 0.000 description 2
- 238000000605 extraction Methods 0.000 description 2
- 239000010408 film Substances 0.000 description 2
- HCDGVLDPFQMKDK-UHFFFAOYSA-N hexafluoropropylene Chemical group FC(F)=C(F)C(F)(F)F HCDGVLDPFQMKDK-UHFFFAOYSA-N 0.000 description 2
- 230000037427 ion transport Effects 0.000 description 2
- 239000011244 liquid electrolyte Substances 0.000 description 2
- 229910003002 lithium salt Inorganic materials 0.000 description 2
- 159000000002 lithium salts Chemical class 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 239000004014 plasticizer Substances 0.000 description 2
- 239000005518 polymer electrolyte Substances 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- YLQBMQCUIZJEEH-UHFFFAOYSA-N tetrahydrofuran Natural products C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 2
- BQCIDUSAKPWEOX-UHFFFAOYSA-N 1,1-Difluoroethene Chemical compound FC(F)=C BQCIDUSAKPWEOX-UHFFFAOYSA-N 0.000 description 1
- TVAJJUOMNRUGQA-UHFFFAOYSA-N 2-butoxyethyl dihydrogen phosphate Chemical compound CCCCOCCOP(O)(O)=O TVAJJUOMNRUGQA-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- KMTRUDSVKNLOMY-UHFFFAOYSA-N Ethylene carbonate Chemical compound O=C1OCCO1 KMTRUDSVKNLOMY-UHFFFAOYSA-N 0.000 description 1
- 229920006370 Kynar Polymers 0.000 description 1
- 229910013462 LiC104 Inorganic materials 0.000 description 1
- 229910000552 LiCF3SO3 Inorganic materials 0.000 description 1
- 229910014549 LiMn204 Inorganic materials 0.000 description 1
- 229910013131 LiN Inorganic materials 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 239000007983 Tris buffer Substances 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 239000010405 anode material Substances 0.000 description 1
- 239000003125 aqueous solvent Substances 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000010406 cathode material Substances 0.000 description 1
- 210000003850 cellular structure Anatomy 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000011530 conductive current collector Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- IEJIGPNLZYLLBP-UHFFFAOYSA-N dimethyl carbonate Chemical compound COC(=O)OC IEJIGPNLZYLLBP-UHFFFAOYSA-N 0.000 description 1
- FBSAITBEAPNWJG-UHFFFAOYSA-N dimethyl phthalate Natural products CC(=O)OC1=CC=CC=C1OC(C)=O FBSAITBEAPNWJG-UHFFFAOYSA-N 0.000 description 1
- 229960001826 dimethylphthalate Drugs 0.000 description 1
- 239000008151 electrolyte solution Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 229910021485 fumed silica Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 239000002650 laminated plastic Substances 0.000 description 1
- 229910001540 lithium hexafluoroarsenate(V) Inorganic materials 0.000 description 1
- 229910002102 lithium manganese oxide Inorganic materials 0.000 description 1
- 229910001496 lithium tetrafluoroborate Inorganic materials 0.000 description 1
- VLXXBCXTUVRROQ-UHFFFAOYSA-N lithium;oxido-oxo-(oxomanganiooxy)manganese Chemical compound [Li+].[O-][Mn](=O)O[Mn]=O VLXXBCXTUVRROQ-UHFFFAOYSA-N 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000000638 solvent extraction Methods 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 230000032258 transport Effects 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/46—Separators, membranes or diaphragms characterised by their combination with electrodes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/05—Accumulators with non-aqueous electrolyte
- H01M10/052—Li-accumulators
- H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/05—Accumulators with non-aqueous electrolyte
- H01M10/052—Li-accumulators
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
- H01M4/621—Binders
- H01M4/622—Binders being polymers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/411—Organic material
- H01M50/414—Synthetic resins, e.g. thermoplastics or thermosetting resins
- H01M50/417—Polyolefins
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/431—Inorganic material
- H01M50/434—Ceramics
- H01M50/437—Glass
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/449—Separators, membranes or diaphragms characterised by the material having a layered structure
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/449—Separators, membranes or diaphragms characterised by the material having a layered structure
- H01M50/451—Separators, membranes or diaphragms characterised by the material having a layered structure comprising layers of only organic material and layers containing inorganic material
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/449—Separators, membranes or diaphragms characterised by the material having a layered structure
- H01M50/454—Separators, membranes or diaphragms characterised by the material having a layered structure comprising a non-fibrous layer and a fibrous layer superimposed on one another
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/44—Fibrous material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Inorganic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Ceramic Engineering (AREA)
- Secondary Cells (AREA)
- Cell Separators (AREA)
Abstract
A lithium ion cell with a polymeric anode and cathode and a separator therebetween. The separator, such as of non-woven polymeric fibers is provided with its own discrete structure, without carrier substrate, and with structural integrity, apart from being laminated/compressed between the polymeric anode and cathode elements. Operable cells are made thinner despite the self supporting discrete structure, with obtained improved rate capacity and high temperature performance.
Description
LITHIUM ION POLYMER CELL SEPARATOR
FIELD OF THE INVENTION
This invention relates to separators used in thin laminated electrochemical cells and particularly to separators used in lithium ion polymer cells.
BACKGROUND OF THE INVENTION
In polymer type cells the individual cells are typically constructed with the cathode and anode materials being laminated to opposite sides of a thin solid polymer electrolyte separator membrane, with respective electrically conductive current collectors being placed adjacent to or within the anode and cathode. The anode, cathode, current collectors and separator together with electrolyte comprise the individual cell assembly which is typically placed into a metallized plastic laminate which is sealed under heat and pressure to form a completed sealed cell, with the respective current collectors remaining electrically externally accessible. The respective layers of the electrodes and electrolyte separator are very thin, generally on the order of 5-6 mils for the anode, 9-12 mils for the cathode and 3-9 mils for the polymer electrolyte/separator, with a total cell thickness of about 18-25 mils.
In the past, in such polymeric cells, the polymeric materials of the electrodes and separator have been of the same or very similar material. The cells were made with a lamination compression of the thin separator between the electrodes to enhance interface contact by means of a common material interface. The enhanced interfacial contact was deemed necessary to provide for sufficient ion transport capability through the separator to the electrodes, which ion transport had been minimized because of the low amounts of fluid electrolyte contained in polymer cells. Polymer cells contain all or nearly all of their electrolyte as absorbed within the electrodes and separator with little if any free liquid electrolyte. It was thus deemed necessary to provide a pressed laminate structure SUBSTITUTE SHEET (RULE 26) WO 99/19920 PCTlUS98/21481 with all components having common polymeric components in order to provide the requisite interface for acceptable cell and battery performance. Accordingly, in polymer cells the separator was in the form of a thin membrane of the common polymeric material, having little structural integrity of its own. Accordingly the separator was required to be handled during cell and battery construction on a base substrate as a carrier until the separator was laminated with the electrodes, at which point the carrier substrate was removed.
However, despite the integration of anode, cathode and separator in polymer cells, as described, there were often fluctuations in cell performance in terms of cell rate, capacity and high temperature performance. This was in addition to the complications in manufacturing engendered by construction of such cells with component carrier substrates and the sensitivity of the material to mechanical handling.
By way of specific example, in a typical polymeric cell, the cell anode, cathode and separator are each comprised of a combination of a poly(vinylidene fluoride) (PVdF) copolymer matrix and a compatible organic plasticizes which maintains a homogeneous composition in the form of a film. In commercial embodiments, the separator copolymer composition comprises from about 75 to about 92~ by weight of the poly(vinylidene fluoride) and about 8 to about 25~ by weight hexafluoropropylene (HFP), (both commercially available from Elf AtoChem North America as Kynar FLEXt'"), and an organic plasticizes. The copolymer composition is also used as binder material in the manufacture of the respective electrodes to insure a compatible interface with the separator.
The most common organic plasticizes materials are the higher-boiling point plasticizers including dibutyl phthalate, dimethyl phthalate, diethyl phthalate and tris butoxyethyl phosphate. In addition, inorganic fillers such as fumed alumina SUBSTITUTE SHEET (RULE 26) _ WO 99/19920 PCT/US98/Z1481 and silanized fumed silica were often added to enhance the physical strength and melt viscosity of the separator membrane, and to increase the electrolyte solution absorption level.
Because of the requisite thin film nature of the separators they were commonly made by procedures involving casting or forming films in addition to the described use of substrate carried membranes of polymer compositions.
In a typical lithium ion polymer cell the cathode is generally made of the polymer used in the anode and separator, with an amount of lithium manganese oxide added to the mix in place of the graphite (used in the anode) as a host intercalation material for the lithium ions.
The current collectors which are assembled to be in intimate electrical contact with the cathode and the anode are usually made from aluminum and copper, respectively, and of foil or grid-like configuration.
To facilitate ionic conductivity and transport, the anode, cathode and separator (usually as a unit, after lamination and compresion) are made porous by solvent extraction of the plasticizer material such as DHP, which, after the extraction, leaves matrices or pores in the electrodes and separator. It is understood however, that this is merely an illustrative embodiment and that other methods of extraction are possible, as well as other methods for providing the requisite porosity. The porous electrodes and separator are dipped into the electrolyte, prior to cell packaging, in order to load the electrolyte into the cell. Free liquid electrolyte is minimized or eliminated thereby.
The electrolyte, which is added to the electrodes and separator is comprised of a solution of a soluble lithium salt in one or more organic solvents such as ethylene carbonate and dimethyl carbonate (EC-DMC). Other commonly utilized non-aqueous solvents include y-butyrolactone (Y-BL), tetrahydrofuran (THF), 1,2-dimethoxyethane (1,2-DME), propylene carbonate (PC), SUBSTITUTE SHEET (RULE 2B) diethyl carbonate (DEC), methyl ethyl carbonate (MEC), diethoxyethane (DEE), dioxolane (DOL) and methyl formate (MF).
Generally the soluble electrolyte is present in about 1 to 2 molar solutions and with preferred and common soluble electrolyte lithium salts being LiPFs, LiAsF6, LiBF4, LiC104, LiCF3S03, LiN (CF3S02) 3, and LiN (CzF5S02) 3, with LiPFs being particularly preferred.
Electrodes, anodes and cathodes type, structure and method of construction of polymer type cells are known in the field (e. g., such as described in US Patent No. 5,296,318) with carbon anodes and spinel cathodes such as of LiMn204 and electrolyte containing separators, as described.
SL>l~iARY OF THE INVENTION
With the aforementioned background, it is an object of the present invention to enhance manufacturability of lithium ion polymer cells but without degradation of cell capacity and performance.
It is a further object of the present invention to provide greater uniformity in cell performance.
It is yet another object of the present invention to provide specific components and a method of cell construction with such components, in lithium ion polymer cells, which provide enhanced cell performance in addition to overall uniformity of such performance.
Generally the present invention comprises a lithium ion polymer cell in which the separator component is a discrete self supporting element without substrate carrier. The separator comprises a porous non-woven material comprised of polymeric fibers which need not be the same polymer contained in the anode and cathode. The separator is used in its self supporting form, with a minimum thickness of about 1 mil (0.001") and preferably about 25 mils with a substantial weight/unit area of at least about 20 gm/m2 and more preferably about 25-28 gm/mz. The discrete separator may be used without carrier substrate, with SUBSTITUTE SHEET (RULE 261 _ WO 99/19920 PC'f/US98/21481 the anode and cathode being directly laminated thereon, as with the membrane lamination. Alternatively, the discrete separator is coated on both sides (or coated on one side and allowed to seep to the other side) with a thin layer of the common polymeric material of the anode and cathode whereby it effectively functions as a separator element and a non-removed in situ carrier substrate for a separator of the common polymeric material of the anode and cathode.
A preferred material for the self supporting separator of the present invention is melt blown nonwoven polypropylene commercially available from Johns Manville as Grade material PX0074, having a weight of 28 gm/m2 with a thickness of 0.0025"
and a high porosity. Other non woven or fibrous polymeric materials, inert to the cell components may similarly be utilized, such as of PVC, polyethylene and the like or non-polymeric materials such as fibrous glass, glass mat, etc.
In accordance with the present invention, manufacturability is enhanced since the separator can be handled and positioned without a carrier base and the removal thereof, with the material being ruggeder. Other manufacturing steps of lamination placement of anode and cathode remain the same.
Surprisingly it has beeen found that not only is performance not degraded with the use of a discrete separator of a non-common material but overall cell performance can be actually enhanced, with enhanced uniformity of cell characteristics and structural integrity.
DETAILED DESCRIPTION OF THE INVENTION
In order to test and demonstrate the efficacy of the present invention two groups of identical lithium ion polymer cells were identically constructed and tested except that one group (Example 1, with 31 cells) was made with the membrane separators comprised of PVdF copolymer matrix, of the prior art, as specifically described above, on carrier substrates, which were removed during the construction thereof, with lamination of SU8ST1TUTE SHEET (RULE 26) WO 99/19920 PCf/US98/21481 anode and cathode thereto. The other group of cells (Example 2, with 16 cells) was constructed with the Johns Manville grade PX0074 melt blown polypropylene nonwoven, described above, as discrete separators, in place of the substrate carried membrane separator, and coated on both sides with PVdF to an extent sufficient to increase the weight thereof by about 50~, after which the anode and cathode were laminated to the coated separator. Both groups of cells were placed under charge regimen of 4.2v constant voltage chage limiting current to a 0.2A (C rate) until the current fell below C/20 or 2.5 hours to provide a charge profile; and a discharge regimen of constant current discharge at 0.2A to a 3.0 volt cutoff to provide a discharge regimen. The results of the testing for both groups of cells are given in the following Tables 1 and 2.
FIELD OF THE INVENTION
This invention relates to separators used in thin laminated electrochemical cells and particularly to separators used in lithium ion polymer cells.
BACKGROUND OF THE INVENTION
In polymer type cells the individual cells are typically constructed with the cathode and anode materials being laminated to opposite sides of a thin solid polymer electrolyte separator membrane, with respective electrically conductive current collectors being placed adjacent to or within the anode and cathode. The anode, cathode, current collectors and separator together with electrolyte comprise the individual cell assembly which is typically placed into a metallized plastic laminate which is sealed under heat and pressure to form a completed sealed cell, with the respective current collectors remaining electrically externally accessible. The respective layers of the electrodes and electrolyte separator are very thin, generally on the order of 5-6 mils for the anode, 9-12 mils for the cathode and 3-9 mils for the polymer electrolyte/separator, with a total cell thickness of about 18-25 mils.
In the past, in such polymeric cells, the polymeric materials of the electrodes and separator have been of the same or very similar material. The cells were made with a lamination compression of the thin separator between the electrodes to enhance interface contact by means of a common material interface. The enhanced interfacial contact was deemed necessary to provide for sufficient ion transport capability through the separator to the electrodes, which ion transport had been minimized because of the low amounts of fluid electrolyte contained in polymer cells. Polymer cells contain all or nearly all of their electrolyte as absorbed within the electrodes and separator with little if any free liquid electrolyte. It was thus deemed necessary to provide a pressed laminate structure SUBSTITUTE SHEET (RULE 26) WO 99/19920 PCTlUS98/21481 with all components having common polymeric components in order to provide the requisite interface for acceptable cell and battery performance. Accordingly, in polymer cells the separator was in the form of a thin membrane of the common polymeric material, having little structural integrity of its own. Accordingly the separator was required to be handled during cell and battery construction on a base substrate as a carrier until the separator was laminated with the electrodes, at which point the carrier substrate was removed.
However, despite the integration of anode, cathode and separator in polymer cells, as described, there were often fluctuations in cell performance in terms of cell rate, capacity and high temperature performance. This was in addition to the complications in manufacturing engendered by construction of such cells with component carrier substrates and the sensitivity of the material to mechanical handling.
By way of specific example, in a typical polymeric cell, the cell anode, cathode and separator are each comprised of a combination of a poly(vinylidene fluoride) (PVdF) copolymer matrix and a compatible organic plasticizes which maintains a homogeneous composition in the form of a film. In commercial embodiments, the separator copolymer composition comprises from about 75 to about 92~ by weight of the poly(vinylidene fluoride) and about 8 to about 25~ by weight hexafluoropropylene (HFP), (both commercially available from Elf AtoChem North America as Kynar FLEXt'"), and an organic plasticizes. The copolymer composition is also used as binder material in the manufacture of the respective electrodes to insure a compatible interface with the separator.
The most common organic plasticizes materials are the higher-boiling point plasticizers including dibutyl phthalate, dimethyl phthalate, diethyl phthalate and tris butoxyethyl phosphate. In addition, inorganic fillers such as fumed alumina SUBSTITUTE SHEET (RULE 26) _ WO 99/19920 PCT/US98/Z1481 and silanized fumed silica were often added to enhance the physical strength and melt viscosity of the separator membrane, and to increase the electrolyte solution absorption level.
Because of the requisite thin film nature of the separators they were commonly made by procedures involving casting or forming films in addition to the described use of substrate carried membranes of polymer compositions.
In a typical lithium ion polymer cell the cathode is generally made of the polymer used in the anode and separator, with an amount of lithium manganese oxide added to the mix in place of the graphite (used in the anode) as a host intercalation material for the lithium ions.
The current collectors which are assembled to be in intimate electrical contact with the cathode and the anode are usually made from aluminum and copper, respectively, and of foil or grid-like configuration.
To facilitate ionic conductivity and transport, the anode, cathode and separator (usually as a unit, after lamination and compresion) are made porous by solvent extraction of the plasticizer material such as DHP, which, after the extraction, leaves matrices or pores in the electrodes and separator. It is understood however, that this is merely an illustrative embodiment and that other methods of extraction are possible, as well as other methods for providing the requisite porosity. The porous electrodes and separator are dipped into the electrolyte, prior to cell packaging, in order to load the electrolyte into the cell. Free liquid electrolyte is minimized or eliminated thereby.
The electrolyte, which is added to the electrodes and separator is comprised of a solution of a soluble lithium salt in one or more organic solvents such as ethylene carbonate and dimethyl carbonate (EC-DMC). Other commonly utilized non-aqueous solvents include y-butyrolactone (Y-BL), tetrahydrofuran (THF), 1,2-dimethoxyethane (1,2-DME), propylene carbonate (PC), SUBSTITUTE SHEET (RULE 2B) diethyl carbonate (DEC), methyl ethyl carbonate (MEC), diethoxyethane (DEE), dioxolane (DOL) and methyl formate (MF).
Generally the soluble electrolyte is present in about 1 to 2 molar solutions and with preferred and common soluble electrolyte lithium salts being LiPFs, LiAsF6, LiBF4, LiC104, LiCF3S03, LiN (CF3S02) 3, and LiN (CzF5S02) 3, with LiPFs being particularly preferred.
Electrodes, anodes and cathodes type, structure and method of construction of polymer type cells are known in the field (e. g., such as described in US Patent No. 5,296,318) with carbon anodes and spinel cathodes such as of LiMn204 and electrolyte containing separators, as described.
SL>l~iARY OF THE INVENTION
With the aforementioned background, it is an object of the present invention to enhance manufacturability of lithium ion polymer cells but without degradation of cell capacity and performance.
It is a further object of the present invention to provide greater uniformity in cell performance.
It is yet another object of the present invention to provide specific components and a method of cell construction with such components, in lithium ion polymer cells, which provide enhanced cell performance in addition to overall uniformity of such performance.
Generally the present invention comprises a lithium ion polymer cell in which the separator component is a discrete self supporting element without substrate carrier. The separator comprises a porous non-woven material comprised of polymeric fibers which need not be the same polymer contained in the anode and cathode. The separator is used in its self supporting form, with a minimum thickness of about 1 mil (0.001") and preferably about 25 mils with a substantial weight/unit area of at least about 20 gm/m2 and more preferably about 25-28 gm/mz. The discrete separator may be used without carrier substrate, with SUBSTITUTE SHEET (RULE 261 _ WO 99/19920 PC'f/US98/21481 the anode and cathode being directly laminated thereon, as with the membrane lamination. Alternatively, the discrete separator is coated on both sides (or coated on one side and allowed to seep to the other side) with a thin layer of the common polymeric material of the anode and cathode whereby it effectively functions as a separator element and a non-removed in situ carrier substrate for a separator of the common polymeric material of the anode and cathode.
A preferred material for the self supporting separator of the present invention is melt blown nonwoven polypropylene commercially available from Johns Manville as Grade material PX0074, having a weight of 28 gm/m2 with a thickness of 0.0025"
and a high porosity. Other non woven or fibrous polymeric materials, inert to the cell components may similarly be utilized, such as of PVC, polyethylene and the like or non-polymeric materials such as fibrous glass, glass mat, etc.
In accordance with the present invention, manufacturability is enhanced since the separator can be handled and positioned without a carrier base and the removal thereof, with the material being ruggeder. Other manufacturing steps of lamination placement of anode and cathode remain the same.
Surprisingly it has beeen found that not only is performance not degraded with the use of a discrete separator of a non-common material but overall cell performance can be actually enhanced, with enhanced uniformity of cell characteristics and structural integrity.
DETAILED DESCRIPTION OF THE INVENTION
In order to test and demonstrate the efficacy of the present invention two groups of identical lithium ion polymer cells were identically constructed and tested except that one group (Example 1, with 31 cells) was made with the membrane separators comprised of PVdF copolymer matrix, of the prior art, as specifically described above, on carrier substrates, which were removed during the construction thereof, with lamination of SU8ST1TUTE SHEET (RULE 26) WO 99/19920 PCf/US98/21481 anode and cathode thereto. The other group of cells (Example 2, with 16 cells) was constructed with the Johns Manville grade PX0074 melt blown polypropylene nonwoven, described above, as discrete separators, in place of the substrate carried membrane separator, and coated on both sides with PVdF to an extent sufficient to increase the weight thereof by about 50~, after which the anode and cathode were laminated to the coated separator. Both groups of cells were placed under charge regimen of 4.2v constant voltage chage limiting current to a 0.2A (C rate) until the current fell below C/20 or 2.5 hours to provide a charge profile; and a discharge regimen of constant current discharge at 0.2A to a 3.0 volt cutoff to provide a discharge regimen. The results of the testing for both groups of cells are given in the following Tables 1 and 2.
SUBSTITUTE SHEET (RULE 26) L
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d n m w a w,. hue.n ~ _"' ~ ~ ~ ~ ~ ~ ~ ~~ H ~ . h ~' 1~. d d d d~ ~
~.
o o d d d d d d do d ~ d c d d ~ ~' R ~
~
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.a ~ o ~ ~ ,,,,~~ ~
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w ~~ v'v o o d ~v dd ~ ~ ~ ~ ~ o ho dd do o o o U a ~ o U 5 " rte.'d ot n e~i ,od s ~ ~ ~ ~ ~ ~
' o Fn a ~~ E H ~ & F F R
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w h 1e UN
SUBSTITUTE SHEET (RULE 26) WO 99!19920 PCT/US98/2I481 so a ,~ o _ ,~.~. ~ ..m .
a ~ 0 m o ~~'~ ~ ~'~~ ~ ~ d ~ i~ ~
' a w v ~v i i i s o W ~ a NI 4 4 0 IO~C o ~
~t n ~'t~ r'iR ~'.~n R R ~'!"!~t~!
%
w w ~-r r ~rw~-r t ".r w~ p 1 . .~
~~eD,$ o ' ~ f~R o V. ~ a~d d d o f oo d d ~ d ov o _ w B ~ ~qR a~m r-s~R~.~ ~ ~ ~.~H $
7 E p ~ ~ ~ ~ s xs ~ g g s sx $
.~~ -r v-~rr ".rv-~ v r v-r.- ~
~~ ~
B
n 8 E ~ R R R ~!r.ro .r 1 v~o ~
~ T ~ ~'~ ~ m a ~ ~ ~o w "
. , N ~ r r ~.vr ~-r-m w ~..~r-~
j r r. r ~
~r ~0 p ~H ~ ~ ~ ~ ~ ~~ ~ lw~.n~.,H ~1~.s G
d d o d a do d d o o do 0 ~
d ~ Q R r ~ a~Q ~ ~i~ ~a 'rr-~"
r H
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C
V o .- v m ~ v ~0 ~
~ ~ ~ ~o ~
W n ~ ~ C1 ~1I~tN NIN 1VN N ~1 t~PI h ' o = a E r h ~ r o r.o~ ~
V
~ 0 V d ~
SUBSTITUTE SHEET (RULE 26) The last column in each Table of OCV after 48 Hrs. is most indicative of cell stability and uniformity of cell performance.
The prior art cells generally exhibited declines in OCV voltage or fluctuations whereas the cells utilizing the discrete separators of the present invention exhibited uniform increase in OCV. The use of the discrete separators accordingly provided the benefits of facilitated manufacture as well as greater consistency of performance.
It is understood that the above description and examples are only exemplary of the present invention and that changes may be made to types, number, configuration and composition of the components of the cells of the present invention without departing from the scope of the present invention as defined in the following claims.
a ~ 0 m o ~~'~ ~ ~'~~ ~ ~ d ~ i~ ~
' a w v ~v i i i s o W ~ a NI 4 4 0 IO~C o ~
~t n ~'t~ r'iR ~'.~n R R ~'!"!~t~!
%
w w ~-r r ~rw~-r t ".r w~ p 1 . .~
~~eD,$ o ' ~ f~R o V. ~ a~d d d o f oo d d ~ d ov o _ w B ~ ~qR a~m r-s~R~.~ ~ ~ ~.~H $
7 E p ~ ~ ~ ~ s xs ~ g g s sx $
.~~ -r v-~rr ".rv-~ v r v-r.- ~
~~ ~
B
n 8 E ~ R R R ~!r.ro .r 1 v~o ~
~ T ~ ~'~ ~ m a ~ ~ ~o w "
. , N ~ r r ~.vr ~-r-m w ~..~r-~
j r r. r ~
~r ~0 p ~H ~ ~ ~ ~ ~ ~~ ~ lw~.n~.,H ~1~.s G
d d o d a do d d o o do 0 ~
d ~ Q R r ~ a~Q ~ ~i~ ~a 'rr-~"
r H
~ _ G ~
~ D
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V o .- v m ~ v ~0 ~
~ ~ ~ ~o ~
W n ~ ~ C1 ~1I~tN NIN 1VN N ~1 t~PI h ' o = a E r h ~ r o r.o~ ~
V
~ 0 V d ~
SUBSTITUTE SHEET (RULE 26) The last column in each Table of OCV after 48 Hrs. is most indicative of cell stability and uniformity of cell performance.
The prior art cells generally exhibited declines in OCV voltage or fluctuations whereas the cells utilizing the discrete separators of the present invention exhibited uniform increase in OCV. The use of the discrete separators accordingly provided the benefits of facilitated manufacture as well as greater consistency of performance.
It is understood that the above description and examples are only exemplary of the present invention and that changes may be made to types, number, configuration and composition of the components of the cells of the present invention without departing from the scope of the present invention as defined in the following claims.
SUBSTITUTE SHEET (RULE 26)
Claims (6)
1. A lithium ion polymer cell having a polymeric anode and cathode, wherein the anode further contains an intercalation carbon material and wherein the cathode contains a material capable of reversibly containing lithium ions, wherein the anode and cathode are laminated on a self supporting discrete separator element.
2. The cell of claim 1, wherein the self supporting discrete separator element is comprised of any one of a melt blown nonwoven polymer or microporous polymer of a thickness in excess of 1 mil.
3. The cell of claim 2, wherein the melt blown nonwoven polymer separator element material is comprised of polypropylene with a unit weight of at least 25 gm/m2.
4. The cell of claim 3, wherein the anode, cathode and separator comprise the same polymer and wherein said same polymer in the separator comprises a coating on the melt blown non-woven polypropylene, with the anode and cathode being laminated on the coating.
5. The cell of claim 1, wherein the self supporting discrete separator is comprised of glass.
6. The cell of claim 5, wherein said glass separator is comprised of glass fibers.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08/948,512 | 1997-10-10 | ||
| US08/948,512 US5962162A (en) | 1997-10-10 | 1997-10-10 | Lithium ion polymer cell separator |
| PCT/US1998/021481 WO1999019920A1 (en) | 1997-10-10 | 1998-10-12 | Lithium ion polymer cell separator |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2305271A1 true CA2305271A1 (en) | 1999-04-22 |
Family
ID=25487934
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002305271A Abandoned CA2305271A1 (en) | 1997-10-10 | 1998-10-12 | Lithium ion polymer cell separator |
Country Status (10)
| Country | Link |
|---|---|
| US (1) | US5962162A (en) |
| EP (1) | EP1029377A1 (en) |
| JP (1) | JP2001520441A (en) |
| KR (1) | KR20010015725A (en) |
| CN (1) | CN1279823A (en) |
| AU (1) | AU1078999A (en) |
| BR (1) | BR9812806A (en) |
| CA (1) | CA2305271A1 (en) |
| NO (1) | NO20001857D0 (en) |
| WO (1) | WO1999019920A1 (en) |
Families Citing this family (17)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6451484B1 (en) * | 1999-04-21 | 2002-09-17 | Samsung Sdi Co., Ltd. | Lithium secondary battery and manufacturing method thereof |
| WO2000077875A1 (en) * | 1999-06-11 | 2000-12-21 | Le Carbone Lorraine | Method for making a multilayer structure for lithium polymer generators |
| SG129214A1 (en) * | 2000-10-12 | 2007-02-26 | Valence Technology Inc | Polymeric mesoporous separator elements for laminated lithium-ion rechargeable batteries |
| KR100399782B1 (en) * | 2001-03-05 | 2003-09-29 | 삼성에스디아이 주식회사 | Lithium ion Secondary battery including the case of which is a pouch and method for manufacturing the same |
| KR100445792B1 (en) * | 2001-06-09 | 2004-08-25 | 한국과학기술연구원 | United lithium electrode with a separator and lithium batteries comprising it |
| DE10240032A1 (en) * | 2002-08-27 | 2004-03-11 | Creavis Gesellschaft Für Technologie Und Innovation Mbh | Ion-conducting battery separator for lithium batteries, process for their production and their use |
| KR100449765B1 (en) * | 2002-10-12 | 2004-09-22 | 삼성에스디아이 주식회사 | Lithium metal anode for lithium battery |
| DE10255122A1 (en) * | 2002-11-26 | 2004-06-03 | Creavis Gesellschaft Für Technologie Und Innovation Mbh | Long-term stable separator for an electrochemical cell |
| DE10255121B4 (en) * | 2002-11-26 | 2017-09-14 | Evonik Degussa Gmbh | Separator with asymmetric pore structure for an electrochemical cell |
| KR100987260B1 (en) * | 2007-07-25 | 2010-10-12 | 주식회사 엘지화학 | Electrochemical Device and Manufacturing Method Thereof |
| EP2523202A1 (en) * | 2011-05-13 | 2012-11-14 | Eika, S.Coop | Electrical double - layer capacitor, and method for manufacturing such a capacitor |
| CN107180998B (en) * | 2017-06-16 | 2019-09-24 | 中国科学院宁波材料技术与工程研究所 | A kind of electrolyte and lithium ion battery |
| EP3987602A4 (en) | 2019-06-20 | 2023-06-28 | Unifrax I LLC | Lightweight nonwoven fiber mats |
| MX2022013561A (en) | 2020-04-30 | 2023-02-01 | Piersica Inc | Solid-state polymer separator for lithium-ion batteries. |
| CN112993379A (en) * | 2021-02-04 | 2021-06-18 | 重庆市紫建新能源有限公司 | High-energy-density quick-charging polymer lithium ion battery and preparation method thereof |
| EP4309237A4 (en) * | 2021-03-17 | 2025-09-24 | Lg Electronics Inc | SEPARATOR STRUCTURE, METHOD FOR PRODUCTION THEREOF AND SECONDARY BATTERY THEREOF |
| WO2024107405A1 (en) | 2022-11-14 | 2024-05-23 | Piersica, Inc. | Polymer composition and methods for making same |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS618854A (en) * | 1984-06-22 | 1986-01-16 | Nippon Telegr & Teleph Corp <Ntt> | Cell and its manufacturing method |
| US4794057A (en) * | 1987-07-17 | 1988-12-27 | Duracell Inc. | Separator for electrochemical cells |
| US5180647A (en) * | 1989-09-18 | 1993-01-19 | Evanite Fiber Corporation | Battery separator and method of making same |
| US5176968A (en) * | 1990-12-27 | 1993-01-05 | Duracell Inc. | Electrochemical cell |
| US5591542A (en) * | 1993-02-09 | 1997-01-07 | Sumitomo Electric Industries, Ltd. | Battery diaphragm and battery with such a diaphragm |
| US5460904A (en) * | 1993-08-23 | 1995-10-24 | Bell Communications Research, Inc. | Electrolyte activatable lithium-ion rechargeable battery cell |
-
1997
- 1997-10-10 US US08/948,512 patent/US5962162A/en not_active Expired - Lifetime
-
1998
- 1998-10-12 JP JP2000516383A patent/JP2001520441A/en active Pending
- 1998-10-12 BR BR9812806-0A patent/BR9812806A/en not_active Application Discontinuation
- 1998-10-12 CN CN98811229A patent/CN1279823A/en active Pending
- 1998-10-12 KR KR1020007003838A patent/KR20010015725A/en not_active Ceased
- 1998-10-12 CA CA002305271A patent/CA2305271A1/en not_active Abandoned
- 1998-10-12 WO PCT/US1998/021481 patent/WO1999019920A1/en not_active Ceased
- 1998-10-12 AU AU10789/99A patent/AU1078999A/en not_active Abandoned
- 1998-10-12 EP EP98953399A patent/EP1029377A1/en not_active Withdrawn
-
2000
- 2000-04-06 NO NO20001857A patent/NO20001857D0/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| WO1999019920A1 (en) | 1999-04-22 |
| US5962162A (en) | 1999-10-05 |
| JP2001520441A (en) | 2001-10-30 |
| NO20001857D0 (en) | 2000-04-06 |
| KR20010015725A (en) | 2001-02-26 |
| CN1279823A (en) | 2001-01-10 |
| BR9812806A (en) | 2000-10-03 |
| EP1029377A1 (en) | 2000-08-23 |
| AU1078999A (en) | 1999-05-03 |
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| FZDE | Discontinued |