Title of Invention

ORGANIC/INORGANIC COMPOSITE POROUS FILM FOR A SEPARATOR OF AN ELECTROCHEMICAL DEVICE, METHOD FOR MANUFACTURING THE SAME AND ELECTROCHEMICAL DEVICE PREPARED THEREBY

Abstract Disclosed is an organic/inorganic composite porous film comprising: (a) inorganic particles; and (b) a binder polymer coating layer formed partially or totally on surfaces of the inorganic particles, wherein the inorganic particles are interconnected among themselves and are fixed by the binder polymer, and interstitial volumes among the inorganic particles form a micropore structure. A method for manufacturing the same film and an electrochemical device including the same film are also disclosed. An electrochemical device comprising the organic/inorganic composite porous film shows improved safety and quality.
Full Text Technical Field
[1] The present invention relates to a novel organic/inorganic composite porous film
that can show excellent thermal safety and lithium ion conductivity and a high degree
of swelling with electrolyte compared to conventional polyolefin-based separators, and
an electrochemical device comprising the same, which ensures safety and has
improved quality.
Background Art
[2] Recently, there is an increasing interest in energy storage technology. Batteries
have been widely used as energy sources in portable phones, camcorders, notebook
computers, PCs and electric cars, resulting in intensive research and development into
them. In this regard, electrochemical devices are subjects of great interest. Particularly,
development of rechargeable secondary batteries is the focus of attention.
[3] Secondary batteries are chemical batteries capable of repeated charge and
discharge cycles by means of reversible interconversion between chemical energy and
electric energy, and may be classified into Ni-MH secondary batteries and lithium
secondary batteries. Lithium secondary batteries include lithium secondary metal
batteries, lithium secondary ion batteries, lithium secondary polymer batteries, lithium
secondary ion polymer batteries, etc.
[4] Because lithium secondary batteries have drive voltage and energy density higher
than those of conventional batteries using aqueous electrolytes (such as Ni-MH
batteries), they are produced commercially by many production companies. However,
most lithium secondary batteries have different safety characteristics depending on
several factors. Evaluation of and security in safety of batteries are very important
matters to be considered. Therefore, safety of batteries is strictly restricted in terms of
ignition and combustion in batteries by safety standards.
[5] Currently available lithium ion batteries and lithium ion polymer batteries use
polyolefin-based separators in order to prevent short circuit between a cathode and an
anode. However, because such polyolefin-based separators have a melting point of 200
°C or less, they have a disadvantage in that they can be shrunk or molten to cause a
change in volume when the temperature of a battery is increased by internal and/or

external factors. Therefore, there is a great possibility of short-circuit between a
cathode and an anode caused by shrinking or melting of separators, resulting in
accidents such as explosion of a battery caused by emission of electric energy. As a
result, it is necessary to provide a separator that does not cause heat shrinking at high
temperature.
[6] To solve the above problems related with polyolefin-based separators, many
attempts are made to develop an electrolyte using an inorganic material serving as a
substitute for a conventional separator. Such electrolytes may be broadly classified into
two types. The first type is a solid composite electrolyte obtained by using inorganic
particles having lithium ion conductivity alone or by using inorganic particles having
lithium ion conductivity mixed with a polymer matrix. See, Japanese Laid-Open Patent
No. 2003-022707, ['Solid State fonics'-vol.158, n.3, p.275, (2003)], ['Journal of Power
Sources'-vol.m, n.1, p.209, (2002)], ['Electrochimica Acta'-vol.48, n.14, p.2003,
(2003)], etc. However, it is known that such composite electrolytes are not advisable,
because they have low ion conductivity compared to liquid electrolytes and the in-
terfacial resistance between the inorganic materials and the polymer is high while they
are mixed.
[7] The second type is an electrolyte obtained by mixing inorganic particles having
lithium ion conductivity or not with a gel polymer electrolyte formed of a polymer and
liquid electrolyte. In this case, inorganic materials are introduced in a relatively small
amount compared to the polymer and liquid electrolyte, and thus merely have a sup-
plementary function to assist in lithium ion conduction made by the liquid electrolyte.
[8] However, because electrolytes prepared as described above have no pores therein
or, if any, have pores with a size of several angstroms and low porosity, formed by in-
troduction of an artificial plasticizer, the electrolytes cannot serve sufficiently as
separator, resulting in degradation in the battery quality.
Disclosure
[9] We have found that an organic/inorganic composite porous film, formed by using
(1) inorganic particles and (2) a binder polymer, improves poor thermal safety of a
conventional polyolefin-based separator. Additionally, we have found that because the
organic/inorganic composite porous film has a micropore structure formed by the
inorganic particles present in the film, it provides an increased volume of space into
which a liquid electrolyte infiltrates, resulting in improvements in lithium ion con-
ductivity and degree of swelling with electrolyte. Therefore, the organic/inorganic
composite porous film can improve the quality and safety of an electrochemical device

using the same as separator.
[10] Therefore, it is an object of the present invention to provide an organic/inorganic
composite porous film capable of improving the quality and safety of an elec-
trochemical device, a method for manufacturing the same and an electrochemical
device comprising the same.
[11] According to an aspect of the present invention, there is provided an organic/
inorganic composite porous film, which comprises (a) inorganic particles; and (b) a
binder polymer coating layer formed partially or totally on the surface of the inorganic
particles, wherein the inorganic particles are interconnected among themselves and are
fixed by the binder polymer, and interstitial volumes among the inorganic particles
form a micropore structure. There is also provided an electrochemical device
(preferably, a lithium secondary battery) comprising the same.
[12] According to another aspect of the present invention, there is provided a method
for manufacturing an organic/inorganic composite porous film, which includes the
steps of: (a) dissolving a binder polymer into a solvent to form a polymer solution; (b)
adding inorganic particles to the polymer solution obtained from step (a) and mixing
them; and (c) coating the mixture of inorganic particles with binder polymer obtained
from step (b) on a substrate, followed by drying, and then detaching the substrate.
[13] Hereinafter, the present invention will be explained in more detail.
[14] The present invention is characterized in that it provides a novel organic/inorganic
composite porous film, which serves sufficiently as separator to prevent electrical
contact between a cathode and an anode of a battery and to pass ions therethrough and
shows excellent thermal safety, lithium ion conductivity and degree of swelling with
electrolyte.
[15] The organic/inorganic composite porous film is obtained by using inorganic
particles and a binder polymer. The uniform and heat resistant micropore structure
formed by the interstitial volumes among the inorganic particles permits the organic/
inorganic composite porous film to be used as separator. Additionally, if a polymer
capable of being gelled when swelled with a liquid electrolyte is used as the binder
polymer component, the organic/inorganic composite porous film can serve also as
electrolyte.
[16] Particular characteristics of the organic/ inorganic composite porous film are as
follows.
[17] (1) The organic/inorganic composite porous film according to the present invention
shows improved thermal safety by virtue of the inorganic particles present therein.

[18] In other words, although conventional polyolefin-based separators cause heat
shrinking at high temperature because they have a melting point of 120-140 °C , the
organic/inorganic composite porous film comprising the inorganic particles and binder
polymer does not cause heat shrinking due to the heat resistance of the inorganic
particles. Therefore, an electrochemical device using the above organic/inorganic
composite porous film as separator causes no degradation in safety resulting from an
internal short circuit between a cathode and an anode even under extreme conditions
such as high temperature, overcharge, etc. As a result, such electrochemical devices
have excellent safety characteristics compared to conventional batteries.
[19] (2) Conventional solid electrolytes formed by using inorganic particles and a
binder polymer have no pore structure or, if any, have an irregular pore structure
having a pore size of several angstroms. Therefore, they cannot serve sufficiently as
spacer, through which lithium ions can pass, resulting in degradation in the quality of a
battery. On the contrary, the organic/inorganic composite porous film according to the
present invention has uniform micropore structures formed by the interstitial volumes
among the inorganic particles as shown in FIGs. 1 and 2, and the micropore structures
permit lithium ions to move smoothly therethrough. Therefore, it is possible to
introduce a large amount of electrolyte through the micropore structures so that a high
degree of swelling with electrolyte can be obtained, resulting in improvement in the
quality of a battery.
[20] (3) It is possible to control the pore size and porosity of the organic/inorganic
composite porous film by varying the particle diameter of the inorganic particles and
the mixing ratio of the inorganic particles with the polymer. The micropore structure is
subsequently filled with a liquid electrolyte so that the interfacial resistance generating
among the inorganic particles or between the inorganic particles and the binder
polymer can be reduced significantly.
[21] (4) When the inorganic particles used in the organic/inorganic composite porous
film have a high dielectric constant and/or lithium ion conductivity, the inorganic
particles can improve lithium ion conductivity as well as heat resistance, thereby con-
tributing to improvement of battery quality.
[22] (5) When the binder polymer used in the organic/inorganic composite porous film
is one showing a high degree of swelling with electrolyte, the electrolyte injected after
assemblage of a battery can infiltrate into the polymer and the resultant polymer
containing the electrolyte infiltrated therein has a capability of conducting electrolyte
ions. Therefore, the organic/inorganic composite porous film according to the present

invention can improve the quality of an electrochemical device compared to con-
ventional organic/inorganic composite electrolytes. Additionally, the organic/inorganic
composite porous film provides advantages in that wettability with an electrolyte is
improved compared to conventional hydrophobic polyolefin-based separators, and use
of a polar electrolyte for battery is permitted.
[23] (6) Finally, if the binder polymer is one capable of being gelled when swelled with
electrolyte, the polymer reacts with the electrolyte injected subsequently and is gelled,
thereby forming a gel type organic/inorganic composite electrolyte. Such electrolytes
are produced with ease compared to conventional gel-type electrolytes and show
excellent ion conductivity and a high degree of swelling with electrolyte, thereby con-
tributing to improve the quality of a battery.
[24] One component present in the organic/inorganic composite porous film according
to the present invention is inorganic particles currently used in the art. The inorganic
particles permit interstitial volumes to be formed among them, thereby serving to form
micropores and to maintain the physical shape as spacer. Additionally, because the
inorganic particles are characterized in that their physical properties are not changed
even at a high temperature of 200 °C or higher, the organic/inorganic composite porous
film using the inorganic particles can have excellent heat resistance.
[25] There is no particular limitation in selection of inorganic particles, as long as they
are electrochemically stable. In other words, there is no particular limitation in
inorganic particles that may be used in the present invention, as long as they are not
subjected to oxidation and/or reduction at the range of drive voltages (for example, 0-5
V based on Li/Li+) of a battery, to which they are applied. Particularly, it is preferable
to use inorganic particles having ion conductivity as high as possible, because such
inorganic particles can improve ion conductivity and quality in an electrochemical
device. Additionally, when inorganic particles having a high density are used, they
have a difficulty in dispersion during a coating step and may increase the weight of a
battery to be manufactured. Therefore, it is preferable to use inorganic particles having
a density as low as possible. Further, when inorganic particles having a high dielectric
constant are used, they can contribute to increase the dissociation degree of an
electrolyte salt in a liquid electrolyte, such as a lithium salt, thereby improving the ion
conductivity of the electrolyte.
[26] For these reasons, it is preferable to use inorganic particles having a high dielectric
constant of 5 or more, preferably of 10 or more, inorganic particles having lithium con-
ductivity or mixtures thereof.

[27] Particular non-limiting examples of inorganic particles having a dielectric constant
of 5 or more include BaTiO3 , Pb(Zr,Ti)O3 (PZT), Pb 1-x Lax Zr1-y Tiy O3 (PLZT),

PB(Mg3 Nb2/3 )O3 -PbTiO3 (PMN-PT), hafnia (HfO2), SrTiO3, SnO2, CeO2, MgO, NiO,

CaO, ZnO, ZrO2 , Y2 O3 , Al2O3 , TiO2 , SiC or mixtures thereof.

[28] As used herein, 'inorganic particles having lithium ion conductivity' are referred to
as inorganic particles containing lithium elements and having a capability of
conducting lithium ions without storing lithium. Inorganic particles having lithium ion
conductivity can conduct and move lithium ions due to defects present in their
structure, and thus can improve lithium ion conductivity and contribute to improve
battery quality. Non-limiting examples of such inorganic particles having lithium ion
conductivity include: lithim phosphate (Li3PO4 ), lithium titanium phosphate (LixTiy (PO

4)3, 0
y
-39P2O5, lithium lanthanum titanate (LixLayTiO3, 0
thiophosphate (LixGeyPzSw , 0
,lithium nitrides(LixNy, 0
0
7) such as LiI-Li2S-P2S5 , or mixtures thereof.

[29] According to the present invention, inorganic particles having a relatively high
dielectric constant are used instead of inorganic particles having no reactivity or
having relatively low dielectric constant. Further, the present invention also provides a
novel use of inorganic particles as separators.
[30] The above-described inorganic particles, mat have never been used as separators,
for example Pb(Zr,Ti)O (PZT), Pb1-xLax Zr 1-y Tiy O3 (PLZT), Pb(Mg3 Nb 2/3)O3 -

PbTiO3 (PMN-PT), hafnia (HfO2), etc., have a high dielectric constant of 100 or more.

The inorganic particles also have piezoelectricity so that an electric potential can be
generated between both surfaces by the charge formation, when they are drawn or
compressed under the application of a certain pressure. Therefore, the inorganic
particles can prevent internal short circuit between both electrodes, thereby con-
tributing to improve the safety of a battery. Additionally, when such inorganic particles
having a high dielectric constant are combined with inorganic particles having lithium
ion conductivity, synergic effects can be obtained.
[31] The organic/inorganic composite porous film according to the present invention
can form pores having a size of several micrometers by controlling the size of
inorganic particles, content of inorganic particles and the mixing ratio of inorganic

particles and binder polymer. It is also possible to control the pore size and porosity.
[32] Although there is no particular limitation in size of moronic particles, inorganic
particles preferably have a size of 0.001-10 µm for the purpose of forming a film
having a uniform thickness and providing a suitable porosity. When the size is less
than 0.001 µm , inorganic particles have poor dispersibility so that physical properties
of the organic/inorganic composite porous film cannot be controlled with ease. When
the size is greater than 10 µm, the resultant organic/inorganic composite porous film
has an increased thickness under the same solid content, resulting in degradation in
mechanical properties. Furthermore, such excessively large pores may increase a
possibility of internal short circuit being generated during repeated charge/discharge
cycles.
[33] The inorganic particles are present in the mixture of the inorganic particles with
binder polymer forming the organic/inorganic composite porous film, preferably in an
amount of 50-99 wt%, more particularly in an amount of 60-95 wt% based on 100
wt% of the total weight of the mixture. When the content of the inorganic particles is
less than 50 wt%, the binder polymer is present in such a large amount as to decrease
the interstitial volume formed among the inorganic particles and thus to decrease the
pore size and porosity, resulting in degradation in the quality of a battery. When the
content of the inorganic particles is greater than 99 wt%, the polymer content is too
low to provide sufficient adhesion among the inorganic particles, resulting in
degradation in mechanical properties of a finally formed organic/inorganic composite
porous film.
[34] Another component present i n the organic/inorganic composite porous film
according to the present invention is a binder polymer currently used in the art. The
binder polymer preferably has a glass transition temperature (T )g as low as possible,

more preferably Tg of between -200 °C and 200 °C. Binder polymers having a low Tg

as described above are preferable, because they can improve mechanical properties
such as flexibility and elasticity of a finally formed film. The polymer serves as binder
that interconnects and stably fixes the inorganic particles among themselves, and thus
prevents degradation in mechanical properties of a finally formed organic/inorganic
composite porous film.
[35] When the binder polymer has ion conductivity, it can further improve the quality of
an electrochemical device. However, it is not essential to use a binder polymer having
ion conductivity. Therefore, the binder polymer preferably has a dielectric constant as
high as possible. Because the dissociation degree of a salt in an electrolyte depends on

the dielectric constant of a solvent used in the electrolyte, the polymer having a higher
dielectric constant can increase the dissociation degree of a salt in the electrolyte used
in the present invention. The dielectric constant of the polymer may range from 1.0 to
100 (as measured at a frequency of 1 kHz), and is preferably 10 or more.
[36] In addition to the above-described functions, the binder polymer used in the
present invention may be further characterized in that it is gelled when swelled with a
liquid electrolyte, and thus shows a high degree of swelling. Therefore, it is preferable
to use a polymer having a solubility parameter of between 15 and 45 MPa , more
preferably of between 15 and 25 MPa1 , and between 30 and 45 MPa . Therefore, hy-
drophilic polymers having a lot of polar groups are more preferable than hydrophobic
polymers such as poly olefins. When the binder polymer has a solubility parameter of
less than 15 Mpa or greater than 45 Mpa , it has difficulty in swelling with a con-
ventional liquid electrolyte for battery.
[37] Non-limiting examples of the binder polymer that may be used in the present
invention include polyvinylidene fluoride-co-hexafluoropropylene, polyvinylidene
fluoride-co-trichloroethylene, polymethylmethacrylate, polyacrylonitrile,
polyvinylpyrrolidone, polyvinyl acetate, polyethylene-co-vinyl acetate, polyethylene
oxide, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cya-
noethylpullulan, cyanoethyl polyvinylalcohol, cyanoethylcellulose, cyanoethylsucrose,
pullulan, carboxymetyl cellulose, acrylonitrile-styrene-butadiene copolymer,
polyimide or mixtures thereof. Other materials may be used alone or in combination,
as long as they satisfy the above characteristics.
[38] The organic/inorganic composite porous film may further comprise additives other
than the inorganic particles and binder polymer.
[39] When the organic/inorganic composite porous film is manufactured by using
inorganic particles and a binder polymer, the film may be realized by three types of
embodiments, but is not limited thereto.
[40] The first type is an organic/inorganic composite porous film formed by using a
mixture of inorganic particles and binder polymer with no additional substrate. The
second type is an organic/inorganic composite porous film formed by coating the
mixture on a porous substrate having pores, wherein the film coated on the porous
substrate includes an active layer obtained by coating the mixture of inorganic particles
and binder polymer on the surface of the porous substrate or on a part of the pores in
the substrate. The third type is an organic/inorganic composite porous film formed by
coating the mixture on a cathode and/or an anode. The third type is a monolithic

electrode and film.
[41] In the second embodiment of the organic/inorganic composite porous film
according to the present invention, there is no particular limitation in the substrate
coated with the mixture of inorganic particles and binder polymer, as long as it is a
porous substrate having pores. However, it is preferable to use a heat resistant porous
substrate having a melting point of 200 °C or higher. Such heat resistant porous
substrates can improve the thermal safety of the organic/inorganic composite porous
film under external and/or internal thermal impacts. Non-limiting examples of the
porous substrate having a melting point of 200 °C or higher that may be used include
polyethylene terephthalate, polybutylene terephthalate, polyester, polyacetal,
polyamide, polycarbonate, polyimide, polyetherether ketone, polyether sulfone,
polyphenylene oxide, polyphenylene sulfidro, polyethylene naphthalene or mixtures
thereof. However, other heat resistant engineering plastics may be used with no
particular limitation.
[42] Although there is no particular limitation in thickness of the porous substrate, the
porous substrate preferably has a thickness of between 1 µm and 100 µm, more
preferably of between 5 µm and 50 µm . When the porous substrate has a thickness of
less than 1 µm , it is difficult to maintain mechanical properties. When the porous
substrate has a thickness of greater than 100 µm , it may function as resistance layer.
[43] Although there is no particular limitation in pore size and porosity of the porous
substrate, the porous substrate preferably has a porosity of between 5% and 95%. The
pore size (diameter) preferably ranges from 0.01µm to 50 µm, more preferably from 0.1
µm to 20µm. When the pore size and porosity are less than 0.01 µm and 5%, re-
spectively, the porous substrate may function as resistance layer. When the pore size
and porosity are greater than 50 µm and 95%, respectively, it is difficult to maintain
mechanical properties.
[44] The porous substrate may take the form of a membrane or fiber. When the porous
substrate is fibrous, it may be a nonwoven web forming a porous web (preferably,
spunbond type web comprising long fibers or melt blown type web).
[45] A spunbond process is performed continuously through a series of steps and
provides long fibers formed by heating and melting, which is stretched, in turn, by hot
air to form a web. A melt blown process performs spinning of a polymer capable of
forming fibers through a spinneret having several hundreds of small orifices, and thus
provides three-dimensional fibers having a spider-web structure resulting from inter-
connection of microfibers having a diameter of 10 µm or less.

[46] The organic/inorganic composite porous film that may be formed in various types
of embodiments according to the present invention is characterized in that the film
comprises a micropore structure. First, the organic/inorganic composite porous film
formed by using the mixture of inorganic particles and polymer alone has a micropore
structure formed by interstitial volumes among the inorganic particles serving as
support as well as spacer. Next, the organic/inorganic composite porous film formed
by coating the mixture on a porous substrate has pore structures present both in the
substrate and in the active layer due to the pores present in the porous substrate itself
and interstitial volumes among the inorganic particles in the active layer formed on the
substrate. Finally, the organic/inorganic composite porous film obtained by coating the
mixture on the surface of an electrode has a uniform pore structure formed by in-
terstitial volumes among the inorganic particles in the same manner as the pore
structure formed by electrode active material particles in the electrode. Therefore, any
embodiment of the organic/inorganic composite porous film according to the present
invention has an increased volume of space, into which an electrolyte infiltrates, by
virtue of such micropore structures. As a result, it is possible to increase dispersibility
and conductivity of lithium ions, resulting in improvement in the quality of a battery.
[47] The pore size and porosity of the organic/inorganic composite porous film mainly
depend on the size of inorganic particles. For example, when inorganic particles
having a particle diameter of 1 µmor less are used, pores formed thereby also have a
size of 1 µm or less. The pore structure is filled with an electrolyte injected sub-
sequently and the electrolyte serves to conduct ions. Therefore, the size and porosity of
the pores are important factors in controlling the ion conductivity of the organic/
inorganic composite porous film. Preferably, the pores size and porosity of the
organic/inorganic composite porous film according to the present invention range from
0.01 to 10 µm. and from 5 to 95%, respectively.
[48] There is no particular limitation in thickness of the organic/inorganic composite
porous film according to the present invention. The thickness may be controlled
depending on the quality of a battery. According to the present invention, the film
preferably has a thickness of between 1 and 100 µm, more preferably of between 2 and
30 µm. Control of the thickness of the film may contribute to improve the quality of a
battery.
[49] There is no particular limitation in mixing ratio of inorganic particles to polymer in
the organic/inorganic composite porous film according to the present invention. The
mixing ratio can be controlled according to the thickness and structure of a film to be

formed finally.
[50] The organic/inorganic composite porous film may be applied to a battery together
with a microporous separator (for example, a polyolefin-based separator), depending
on the characteristics of a finally formed battery.
[51] The organic/inorganic composite porous film may be manufactured by a con-
ventional process known to one skilled in the art. One embodiment of a method for
manufacturing the organic/inorganic composite porous film according to the present
invention, includes the steps of: (a) dissolving a binder polymer into a solvent to form
a polymer solution; (b) adding inorganic particles to the polymer solution obtained
from step (a) and mixing them; and (c) coating the mixture obtained from step (b) on
the surface of a substrate, followed by drying, and then detaching the substrate.
[52] Hereinafter, the method for manufacturing the organic/inorganic composite porous
film according to the present invention will be explained in detail.
[53] (1) First, a binder polymer is dissolved in a suitable organic solvent to provide a
polymer solution.
[54] It is preferable that the solvent has a solubility parameter similar to that of the
binder polymer to be used and a low boiling point. Such solvents can be mixed
uniformly with the polymer and can be removed easily after coating the polymer. Non-
limiting examples of the solvent that may be used include acetone, tetrahydrofuran,
methylene chloride, chloroform, dimethylformamide, N-mnethyl-2-pyrrolidone (NMP),
cyclohexane, water and mixtures thereof.
[55] (2) Next, inorganic particles are added to and dispersed in the polymer solution
obtained from the preceding step to provide a mixture of inorganic particles with
binder polymer.
[55] It is preferable to perform a step of pulverizing inorganic particles after adding the
inorganic particles to the binder polymer solution. The time needed for pulverization is
suitably 1-20 hours. The particle size of the pulverized particles ranges preferably from
0.001 and 10 µm. Conventional pulverization methods, preferably a method using a ball
mill may be used.
[57] Although there is no particular limitation in composition of the mixture containing
inorganic particles and binder polymer, such composition can contribute to control the
thickness, pore size and porosity of the organic/inorganic composite porous film to be
formed finally.
[58] In other words, as the weight ratio (I/P) of the inorganic particles (I) to the polymer
(P) increases, porosity of the organic/inorganic composite porous film according to the

present invention increases. Therefore, the thickness of the organic/inorganic
composite porous film increases under the same solid content (weight of the inorganic
particles + weight of the binder polymer). Additionally, the pore size increases in
proportion to the pore formation among the inorganic particles. When the size (particle
diameter) of inorganic particles increases, interstitial distance among the inorganic
particles also increases, thereby increasing the pore size.
[59] (3) The mixture of inorganic particles with binder polymer is coated on a substrate,
followed by drying, and then the substrate is detached to provide the organic/inorganic
composite porous film.
[60] Particular examples of the substrate that may be used include Teflon sheets or the
like generally used in the art, but are not limited thereto.
[61] In order to coat the porous substrate with the mixture of inorganic particles and
binder polymer, any methods known to one skilled in the art may be used. It is possible
to use various processes including dip coating, die coating, roll coating, comma
coating or combinations thereof.
[62] In this step, when the substrate is a porous substrate having pores or a preformed
electrode, various types of organic/inorganic composite porous films can be obtained.
The mixture of inorganic particles and polymer may be coated on the surface of porous
substrate, on the surface of electrode, and on a part of the pores present in the
substrate. In this step, the step of detaching a substrate may be omitted.
[63] The organic/inorganic composite porous film according to the present invention,
obtained as described above, may be used as separator in an electrochemical device,
preferably in a lithium secondary battery. Additionally, the organic/inorganic
composite porous film may be coated with a conventional polymer (for example, a
polymer capable of being swelled with an electrolyte) on one surface or both surfaces
so as to be used as separator.
[64] If the binder polymer used in the film is a polymer capable of being gelled when
swelled with a liquid electrolyte, the polymer may react with the electrolyte injected
after assembling a battery by using the separator, and thus be gelled to form a gel type
organic/inorganic composite electrolyte.
[65] The gel type organic/inorganic composite electrolyte according to the present
invention is prepared with ease compared to gel type polymer electrolytes according to
die prior art, and has a large space to be filled with a liquid electrolyte due to its mi-
croporous structure, thereby showing excellent ion conductivity and a high degree of
swelling with electrolyte, resulting in improvement in the quality of a battery.

[66] Further, the present invention provides an electrochemical device comprising: (a) a
cathode; (b) an anode; (c) the organic/inorganic composite porous film according to
the present invention, interposed between the cathode and anode; and (d) an
electrolyte.
[67] Such electrochemical devices include any devices in which electrochemical
reactions occur and particular examples thereof include all kinds of primary batteries,
secondary batteries, fuel cells, solar cells or capacitors. Particularly, the elec-
trochemical device is a lithium secondary battery including a lithium secondary metal
battery, lithium secondary ion battery, lithium secondary polymer battery or lithium
secondary ion polymer battery.
[68] According to the present invention, the organic/inorganic composite porous film
contained in the electrochemical device serves as separator. If the polymer used in the
film is a polymer capable of being gelled when swelled with electrolyte, the film may
serve also as electrolyte.
[69] In addition to the above organic/inorganic composite porous film, a microporous
separator may also be used. Particular examples of the microporous separator that may
be used includes currently used polyolefin-based separators or at least one porous
substrate having a melting point of 200 °C , selected from the group consisting of
polyethylene terephthalate, polybutylene terephthalate, polyester, polyacetal,
polyamide, polycarbonate, polyimide, polyetherether ketone, polyether sulfone,
polyphenylene oxide, polyphenylene sulfidro and polyethylene naphthalene.
[70] The electrochemical device may be manufactured by a conventional method
known to one skilled in the art. In one embodiment of the method for manufacturing
the electrochemical device, the electrochemical device is assembled by using the
organic/inorganic composite porous film interposed between a cathode and an anode,
and then an electrolyte is injected.
[71] The electrode that may be applied together with the organic/inorganic composite
porous film according to the present invention may be formed by applying an electrode
active material on a current collector according to a method known to one skilled in
the art. Particularly, cathode active materials may include any conventional cathode
active materials currently used in a cathode of a conventional electrochemical device.
Particular non-limiting examples of the cathode active material include lithium in-
tercalation materials such as lithium manganese oxides, lithium cobalt oxides, lithium
nickel oxides, lithium iron oxides or composite oxides thereof. Additionally, anode
active materials may include any conventional anode active materials currently used in

an anode of a conventional electrochemical device. Particular non-limiting examples
of the anode active material include lithium intercalation materials such as lithium
metal, lithium alloys, carbon, petroleum coke, activated carbon, graphite or other car-
bonaceous materials. Non-limiting examples of a cathode current collector include foil
formed of aluminum, nickel or a combination thereof. Non-limiting examples of an
anode current collector include foil formed of copper, gold, nickel, copper alloys or a
combination thereof.
[72] The electrolyte that may be used in the present invention includes a salt
represented by the formula of A B , wherein A represents an alkali metal cation
selected from the group consisting of Li+, Na+, K+ and combinations thereof, and B
represents an anion selected from the group consisting of PF6- , BF4- , Cl-, Br-, I, ClO4- ,

AsF6 -, CH3CO2-, CF3SO3-, N(CF3SO2)2-, C(CF2SO2)3- and combinations thereof, the

salt being dissolved or dissociated in an organic solvent selected from the group
consisting of propylene carbonate (PC), ethylene carbonate (EC), diethyl carbonate
(DEC), dimethyl carbonate (DMC), dipropyl carbonate (DPC), dimethyl sulfoxide,
acetonitrile, dimethoxyethane, diethoxyethane, tetrahydrofuran, N-
methyl-2-pyrrolidone (NMP), ethylmethyl carbonate (EMC), gamma-butyrolactone
(GBL) and mixtures thereof. However, the electrolyte that may be used in the present
invention is not limited to the above examples.
[73] More particularly, the electrolyte may be injected in a suitable step during the man-
ufacturing process of an electrochemical device, according to the manufacturing
process and desired properties of a final product. In other words, electrolyte may be
injected, before an electrochemical device is assembled or in a final step during the
assemblage of an electrochemical device.
[74] Processes that may be used for applying the organic/inorganic composite porous
film to a battery include not only a conventional winding process but also a lamination
(stacking) and folding process of a separator and electrode.
[75] When the organic/inorganic composite porous film according to the present
invention is applied to a lamination process, it is possible to significantly improve the
thermal safety of a battery, because a battery formed by a lamination and folding
process generally shows more severe heat shrinking of a separator compared to a
battery formed by a winding process. Additionally, when a lamination process is used,
there is an advantage in that a battery can be assembled with ease by virtue of excellent
adhesion of the polymer present in the organic/inorganic composite porous film
according to the present invention. In this case, the adhesion can be controlled

depending on the content of inorganic particles and polymer, and properties of the
polymer. More particularly, as the polarity of the polymer increases and as the glass
transition temperature (T g) or melting point (Tm ) of the polymer decreases, higher

adhesion between the organic/inorganic composite porous film and electrode can be
obtained.
Description of Drawings
[76] The foregoing and other objects, features and advantages of the present invention
will become more apparent from the following detailed description when taken in
conjunction with the accompanying drawings in which:
[77] FIG. 1 is a schematic view showing an organic/inorganic composite porous film
according to the present invention;
[78] FIG. 2 is a photograph taken by Scanning Electron Microscope (SEM) showing the
organic/inorganic composite porous film (PVdF-HFP/BaTiO3) according to Example

I;
[79] FIG. 3 is a photograph taken by SEM showing a polyolefin-based separator
(PP/PE/PP) used in Comparative Example 1;
[80] FIG. 4 is a photograph taken by SEM showing a porous film manufactured by
using a plasticizer according to Comparative Example 4;
[81] FIG. 5 is a photograph showing the organic/inorganic composite porous film
(PVdF-HFP/BaTiO3) according to Example 1 compared to a currently used PP/PE/PP
separator and PE separator, after each of the samples is maintained at 150 °C for 1
hour;
[82] FIG. 6 is a picture showing the results of an overcharge test for the lithium
secondary battery including a currently used PP/PE/PP separator according to
Comparative Example 1 and the battery including the organic/inorganic composite
porous film (PVdF-HFP/BaTiO3) according to Example 1; and
[83] FIG. 7 is a graph showing variations in ion conductivity depending on the content
of inorganic particles, in the organic/inorganic composite porous film according to the
present invention.
Mode for Invention
[84] Reference will now be made in detail to the preferred embodiments of the present
invention. It is to be understood that the following examples are illustrative only and
the present invention is not limited thereto.
[85] Reference Example. Variations in ion conductivity depending on
content of inorganic particles

[86] The organic/inorganic composite system according to the present invention was
observed to determine variations in ion conductivity depending on the content of
inorganic particles.
[87] The organic/inorganic composite film according to the present invention was
dipped into the electrolyte formed of ethylene carbonate/propylene carbonate/diethyl
carbonate (EC/PC/DEC= 30:20:50 on the basis of wt%) containing 1M lithium hex-
afluorophosphate (LiPF6 ) dissolved therein. The film, into which the electrolyte is im-

pregnated, was measured for ion conductivity by using Metrohm 712 instrument at a
temperature of 25 °C.
[88] As shown in FIG. 7, as the content of inorganic particles increases, ion con-
ductivity also increases. Particularly, when 50 wt% or more of inorganic particles are
used, ion conductivity increases significantly.
[89] [EXAMPLE 1-9]
[90] Preparation of organic/inorganic composite porous film and
Manufacture of lithium secondary battery using the same
[91] Example 1
[92] 1-1. Preparation of organic/inorganic composite porous film (PVdF-HFP/BaTiO3)
[93] PVdF-HFP polymer (polyvinylidene fluoride-hexafluoropropylene copolymer) was
added to tetrahydrofuran (THF) in the amount of about 5 wt% and dissolved therein at
50 °C for about 12 hours or more to form a polymer solution. To the polymer solution
obtained as described above, BaTiO powder having a particle diameter of about 400
nm was added with the concentration of 20 wt% on the total solid content basis, and
then dispersed to form a mixed solution (BaTiO 3/PVDF-HFP= 80:20 (weight ratio)).

Then, the mixed solution obtained as described above was coated on a Teflon sheet by
using a doctor blade coating method. After coating, THF was dried and the Teflon
sheet was detached to obtain a final organic/inorganic composite porous film (see,
FIG. 1). The final film had a thickness of about 30 µm. After measuring with a
porosimeter, the final organic/inorganic composite porous film had a pore size of 0.4
µm and a porosity of 60%.
[94] 1-2. Manufacture of lithium secondary battery
[95] (Manufacture of cathode)
[96] To N-methyl-2-pyrrolidone (NMP) as a solvent, 94 wt% of lithium cobalt
composite oxide (LiCoO2) as cathode active material, 3 wt% of carbon black as

conductive agent and 3 wt% of PVdF (polyvinylidene fluoride) as binder were added
to form slurry for a cathode. The slurry was coated on Al foil having a thickness of 20

µm as cathode collector and dried to form a cathode.
[97] (Manufacture of anode)
[98] To N-methyl-2-pyrrolidone (NMP) as solvent, 96 wt% of carbon powder as anode
active material, 3 wt% of PVdF (polyvinylidene fluoride) as binder and 1 wt% of
carbon black as conductive agent were added to form mixed slurry for an anode. The
slurry was coated on Cu foil having a thickness of 10 µm as anode collector and dried
to form an anode.
[99] (Manufacture of battery)
[100] The cathode and anode obtained as described above were stacked with the organic/
inorganic composite porous film obtained as described in Example 1-1 to form an
assembly. Then, an electrolyte (ethylene carbonate (EC)/propylene carbonate (PC)/
diethyl carbonate (DEC)= 30: 20:50 (wt%) containing IM of lithium hexafluo-
rophosphate (LiPF6)) was injected thereto to provide a lithium secondary battery.

[101] Example 2
[102] Example 1 was repeated to provide a lithium secondary battery, except that mixed
powder of BaTiO and Al2O3 (weight ratio= 20:80) was used instead of BaTiO3
powder to obtain an organic/inorganic composite porous film (PVdF-HFP/ BaTiO 3-Al2

O3). After measuring with a porosimeter, the final organic/inorganic composite porous
film had a thickness of 25 µm , pore size of 0.3 µm and a porosity of 57%.
[103] Example 3
[104] Example 1 was repeated to provide a lithium secondary battery, except that
PMNPT(lead magnesium niobate-lead titanate) powder was used instead of BaTiO3

powder to obtain an organic/inorganic composite porous film (PVdF-HFP/PMNPT).
After measuring with a porosimeter, the final organic/inorganic composite porous film
had a thickness of 30 µm , pore size of 0.3 µm and a porosity of 60%.
[105] Example 4
[106] Example 1 was repeated to provide a lithium secondary battery, except that PVdF-
HFP was not used but about 2 wt% of carboxymethyl cellulose (CMC) polymer was
added to water and dissolved therein at 60 °C for about 12 hours or more to form a
polymer solution, and the polymer solution was used to obtain an organic/inorganic
composite porous film (CMC/ BaTiO3). After measuring with a porosimeter, the final
.
organic/inorganic composite porous film had a thickness of 25 µm , pore size of 0.4 µm
and a porosity of 58%.
[107] Example 5
[108] Example 1 was repeated to provide a lithium secondary battery, except that PZT

powder was used instead of BaTiO3 powder to obtain an organic/inorganic composite

porous film (PVdF-HFP/PZT). After measuring with a porosimeter, the final organic/
inorganic composite porous film had a thickness of 25 µm , pore size of 0.4 µm and a
porosity of 62%.
[109] Example 6
[110] Example 1 was repeated to provide a lithium secondary battery, except that PLZT
powder was used instead of BaTiO3 powder to obtain an organic/inorganic composite

porous film (PVdF-HFP/PLZT). After measuring with a porosimeter, the final organic/
inorganic composite porous film had a thickness of 25 µm , pore size of 0.3 µm and a
porosity of 58%.
[111] Example 7
[112] Example 1 was repeated to provide a lithium secondary battery, except that HfO
powder was used instead of BaTiO3 powder to obtain an organic/inorganic composite

porous film (PVdF-HFP/HfO2). After measuring with a porosimeter, the final organic/

inorganic composite porous film had a thickness of 28 µm , pore size of 0.4 µm and a
porosity of 60%.
[113] Example 8
[114] Example 1 was repeated to provide a lithium secondary battery, except that lithium
titanium phosphate (LiTi2 (PO4)3) powder having a particle diameter of about 400 nm

was used in an amount of the total solid content of 20 wt%, instead of BaTiO3 powder,

to obtain an organic/inorganic composite porous film (PVdF-HFP/ LiTi2(PO4)3) having

a thickness of about 20 µm. After measuring with a porosimeter, the final organic/
inorganic composite porous film had a pore size of 0.5 µm and porosity of 62%.
[115] Example 9
[116] Example 1 was repeated to provide a lithium secondary battery, except that mixed
powder of BaTiO3 and LiTi2 (PO4)3 (weight ratio= 50:50) was used instead of BaTiO3

powder to obtain an organic/inorganic composite porous film (PVdF-HFP/ LiTi2 (PO4)3

-BaTiO3). After measuring with a porosimeter, the final organic/inorganic composite
porous film had a thickness of 25 µm , pore size of 0.3 µm and a porosity of 60%.
[117] [Comparative Examples 1-4]
[118] Comparative Example 1
[119] Example 1 was repeated to provide a lithium secondary battery, except that a con-
ventional poly propylene/polyethylene/polypropylene (PP/PE/PP) separator (see, FIG.
3) was used.
[120] Comparative Example 2

[121] Example 1 was repeated to provide an organic/inorganic composite porous film
and lithium secondary battery comprising the same, except that BaTiO3 and PVDF-
HFP were used in a weight ratio of 20:80. After measuring the BaTiO3 /PVdF-HFP
with a porosimeter, the final organic/inorganic composite porous film had a pore size
of 0.01 µm or less and a porosity of about 10%.
[122] Comparative Example 3
[123] Example 1 was repeated to provide an organic/inorganic composite porous film
and lithium secondary battery comprising the same, except that LiTi2 (PO4)3 and

PVDF-HFP were used in a weight ratio of 10:90. After measuring the LiTi2(PO4)3 /

PVdF-HFP with a porosimeter, the final organic/inorganic composite porous film had
a pore size of 0.01 µm or less and a porosity of about 5%.
[124] Comparative Example 4. Manufacture of porous film using
plasticizer
[125] Dimethyl carbonate (DMC) was selected as plasticizer and used along with PVdF-
HFP in a ratio of 30:70 (on the wt% basis) and THF as solvent to form a porous film.
Dimetyl carbonate used in the film as plasticizer was extracted from the film by using
methanol to provide a final porous film and a lithium secondary battery comprising the
same. After measuring the porous PVdF-HFP film with a porosimeter, the porous film
had a pore size of 0.01 µm or less and a porosity of about 30% (see, FIG. 4).
[126] Experimental Example 1. Surface analysis of organic/inorganic
composite porous film
[127] The following test was performed to analyze the surface of an organic/inorganic
composite porous film according to the present invention.
[128] The sample used in this test was PVdF-HFP/BaTiO obtained according to
Example 1. As controls, a PP/PE/PP separator according to Comparative Example 1
and the porous film using a plasticizer according to Comparative Example 4 were
used.
[129] When analyzed by using Scanning Electron Microscope (SEM), the PP/PE/PP
separator according to Comparative Example 1 and the porous film according to
Comparative Example 4 showed a conventional microporous structure (see, FIGs. 3
and 4). More particularly, the porous film according to Comparative Example 4 had a
dense pore structure formed independently from the inorganic particles present on the
surface of the film. It is thought that the dense pore structure is formed by artificial
extraction of the plasticizer.
[130] On the contrary, the organic/inorganic composite porous film according to the

present invention showed a micropore structure formed by the inorganic particles as
main component of the film (for example, inorganic particles with a high dielectric
constant and/or lithium ion conductivity). Additionally, it could be seen that the
polymer was coated on the surface of the inorganic particles (see, FIG. 2).
[131] Experimental Example 2. Evaluation of heat shrinkage of organic/
inorganic composite porous film
[132] The following experiment was performed to compare the organic/inorganic
composite porous film with a conventional separator.
[133] The organic/inorganic composite porous film (PVdF-CTFE/BaTiO ) according to
Example 1 was used as sample. A conventional PP/PE/PP separator and PE separator
were used as controls.
[134] Each of the test samples was checked for its heat shrinkage after stored at a high
temperature of 150 °C for 1 hour. The test samples provided different results after the
lapse of 1 hour at 150 °C. The PP/PE/PP separator as control was shrunk due to high
temperature to leave only the outer shape thereof. Similarly, the PE separator was
shrunk to about 1/10 of its original size. On the contrary, the organic/inorganic
composite porous film according to the present invention showed good results with no
heat shrinkage (see, FIG. 5)
[135] As can be seen from the foregoing, the organic/inorganic composite porous film
according to the present invention has excellent thermal safety.
[136] Experimental Example 3. Evaluation for safety of lithium
secondary battery
[137] The following test was performed to evaluate the safety of each lithium secondary
battery comprising the organic/inorganic composite porous film according to the
present invention.
[138] Lithium secondary batteries according to Examples 1-9 were used as samples. As
controls, used were the battery using a currently used PP/PE/PP separator according to
Comparative Example 1, the battery using the BaTiO3/PVdF-HFP film (weight ratio=

20:80 on the wt% basis) as separator according to Comparative Example 2, and the
battery using the LiTi2(PO4)3/PVdF-HFP film (weight ratio= 10:90 on the wt% basis)

as separator according to Comparative Example 3.
[139] 3-1. Hot box test
[140] Each battery was stored at high temperatures of 150 °C and 160 °C for 1 hour and
then checked. The results are shown in the following Table 1.
[141] After storing at high temperatures, the battery using a currently used PP/PE/PP

separator according to Comparative Example 1 caused explosion when stored at 160
°C for 1 hour. This indicates that polyolefin-based separators cause extreme heat
shrinking, melting and breakage when stored at high temperature, resulting in internal
short circuit between both electrodes (i.e., a cathode and an anode) of a battery. On the
contrary, lithium secondary batteries comprising an organic/inorganic composite
porous film according to the present invention showed such a safe state as to prevent
firing and burning even at a high temperature of 160 °C (see, Table 1).
[142] Therefore, it can be seen that the lithium secondary battery comprising an organic/
inorganic composite porous film according to the present invention has excellent
thermal safety.
[143]
[144] 3-2. Overcharge test
[145] Each battery was charged under the conditions of 6V/1A and 10V/1A and then
checked. The results are shown in the following Table 2.
[146] After checking, the battery using a currently used PP/PE/PP separator according to
Comparative Example 1 exploded (see, FIG. 6). This indicates that the polyolefin-
based separator is shrunk by overcharge of the battery to cause short circuit between
electrodes, resulting in degradation in safety of the battery. On the contrary, each
lithium secondary battery comprising an organic/inorganic composite porous film
according to the present invention showed excellent safety under overcharge
conditions (see, Table 2 and FIG. 6).
[147] [Table 2]



[148] Experimental Example 4. Evaluation for quality of lithium se
condary battery
[149] The following tests were performed in order to determine the charge/discharge
capacity of each lithium secondary battery comprising an organic/inorganic composite
porous film according to the present invention.
[150] Lithium secondary batteries according to Examples 1-9 were used as samples. As
controls, used were the battery using a currently used PP/PE/PP separator according to
Comparative Example 1, the battery using the BaTiO3/PVdF-HFP film (weight ratio=
20:80 on the wt% basis) as separator according to Comparative Example 2, the battery
using the LiTi2 (PO4)3/PVdF-HFP film (weight ratio= 10:90 on the wt% basis) as

separator according to Comparative Example 3, and the battery using the porous
PVdF-HFP film obtained by using a plasticizer as separator according to Comparative
Example 4.
[151] Each battery having a capacity of 760 mAh was subjected to cycling at a discharge
rate of 0.5C, 1C and 2C. The following Table 3 shows the discharge capacity of each
battery, the capacity being expressed on the basis of C-rate characteristics.
[152] After performing the test, the battery according to Comparative Examples 2 using,
as separator, an organic/inorganic composite porous film that includes a mixture
containing inorganic particles with a high dielectric constant and a binder polymer in a
ratio of 20:80 (on the wt% basis) and the battery according to Comparative Examples 3
using, as separator, an organic/inorganic composite porous film that includes a mixture
containing inorganic particles with lithium ion conductivity and a binder polymer in a
ratio of 10:90 (on the wt% basis), showed a significant drop in capacity depending on
discharge rates, as compared to the batteries using, as separators, the organic/inorganic
composite porous film obtained from the above Examples according to the present
invention and a conventional polyolefin-based separator (see, Table 3). This indicates

that such relatively low amount of inorganic particles compared to the polymer may
decrease the pore size and porosity in the pore structure formed by interstitial volume
among the inorganic particles, resulting in degradation in the quality of a battery. Ad-
ditionally, the battery using the porous film having a pore structure artificially formed
by using a plasticizer as separator according to Comparative Example 4 also showed a
significant drop in capacity depending on discharge rates in the same manner as the
batteries according to Comparative Examples 2 and 3.
[153] On the contrary, lithium secondary batteries comprising the organic/inorganic
composite porous film according to the present invention showed C-rate characteristics
comparable to those of the battery using a conventional polyolefin-based separator
under a discharge rate of up to 2C (see, Table 3).
[154]
Industrial Applicability
[155] As can be seen from the foregoing, the organic/inorganic composite porous film
according to the present invention comprises inorganic particles and a binder polymer,
wherein the inorganic particles are interconnected among themselves and fixed by the
binder polymer and interstitial volumes among the inorganic particles form a heat
resistant micropore structure. Therefore, it is possible to increase the space to be filled
with an electrolyte, and thus to improve a degree of swelling with electrolyte and
lithium ion conductivity. As a result, the organic/inorganic composite porous film
according to the present invention contributes to improve the thermal safety and
quality of a lithium secondary battery using the same as separator.
[156] While this invention has beqn described in connection with what is presently
considered to be the most practical and preferred embodiment, it is to be understood
that the invention is not limited to the disclosed embodiment and the drawings. On the
contrary, it is intended to cover various modifications and variations within the spirit

and scope of the appended claims.

We Claim:
1. An organic/inorganic composite porous film for a separator of an electrochemical
device, comprising :
(a) inorganic particles; and
(b) a binder polymer coating layer formed partially or totally on surfaces of
the inorganic particles, wherein the inorganic particles are interconnected among
themselves and are fixed by the binder polymer, and interstitial volumes among the
inorganic particles form a micropore structure.

2. The film as claimed in claim 1, wherein the inorganic particles are at least one
selected from the group consisting of: (a) inorganic particles having a dielectric constant
of 5 or more; and (b) inorganic particles having lithium ion conductivity.
3. The film as claimed in claim 2, wherein the inorganic particles having a dielectric
constant of 5 or more are BaTiO3, Pb(Zr,Ti)O3 (PZT), Pb1-xLaxZr1-yTiyO3 (PLZT),
Pb(Mg3Nb2/3)O3-PbTiO3 (PMN-PT), hafnia (HfO2), SrTiO3, SnO2, CeO2, MgO, NiO,
CaO, ZnO, ZrO2, Y2O3, Al2O3,TiO2 or SiC.
4. The film as claimed in claim 2, wherein the inorganic particles having lithium ion
conductivity are at least one selected from the group consisting of: lithim phosphate
(Li3PO4), lithium titanium phosphate (LixTiy(PO4)3, 0 titanium phosphate (LixAlyTiz(PO4)3, 0 (0 germanium thiophosphate (LixGeyPzSw, 0 nitrides(LixNy, 0 type glass (LixPySz, 0 5. The film as claimed in claim 1, wherein the inorganic particles have a size of
between 0.001 µm and 10 µm.
6. The film as claimed in claim 1, wherein the inorganic particles are present in the
mixture of inorganic particles with the binder polymer in an amount of 50-99 wt% based
on 100 wt% of the mixture.
7. The film as claimed in claim 1, wherein the binder polymer has a glass transition
temperature (Tg) of between -200°C and 200°C.
8. The film as claimed in claim 1, wherein the binder polymer has a solubility
parameter of between 15 and 45 MPa1/2.
9. The film as claimed in claim 1, wherein the binder polymer is at least one selected
from the group consisting of polyvinylidene fluoride-co-hexafluoropropylene,
polyvinylidene fluoride-co-trichloroethylene, polymethylmethacrylate, polyacrylonitrile,
polyvinylpyrrolidone, polyvinyl acetate, polyethylene-co-vinyl acetate, polyethylene
oxide, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate,

cyanoethylpullulan, cyanoethyl polyvinylalcohol, cyanoethylcellulose,
cyanoethylsucrose, pullulan, carboxymethyl cellulose, acrylonitrile-styrene-butadiene
copolymer and polyimide.
10. The film as claimed in claim 1, which has a pore size of between 0.001 and 10 µm.
11. The film as claimed in claim 1, which has a porosity of between 5% and 95%.
12. The film as claimed in claim 1, which has a thickness of between 1 and 100 µm.
13. An electrochemical device comprising:

(a) a cathode;
(b) an anode;
(c) an organic/inorganic composite porous film as claimed in any one of
claims 1 to 12, which is interposed between the cathode and anode; and
(d) an electrolyte.

14. The electrochemical device as claimed in claim 13, which is a lithium secondary
battery.
15. The electrochemical device as claimed in claim 13, which comprises a
microporous separator.
16. The electrochemical device as claimed in claim 15, wherein the microporous
separator is a polyolefin-based separator, or at least one porous substrate having a melting
point of 200°C or higher, selected from the group consisting of polyethylene
terephthalate, polybutylene terephthalate, polyester, polyacetal, polyamide,
polycarbonate, polyimide, polyetherether ketone, polyether sulfone, polyphenylene oxide,
polyphenylene sulfide and polyethylene naphthalene.
17. A method for manufacturing an organic/inorganic composite porous film as
claimed in any one of claims 1 to 12, comprising the steps of:

(a) dissolving a binder polymer into a solvent to form a polymer solution;
(b) adding inorganic particles to the polymer solution obtained from step (a) and
mixing them; and
(c) coating the mixture of inorganic particles with binder polymer obtained from
step (b) on a substrate, followed by drying, and then detaching the substrate.
18. A separator for batteries comprising an organic/inorganic composite porous film as
claimed in claim 2, wherein said film comprises at least one inorganic particle selected
from the group consisting of Pb(Zr,Ti)O3 (PZT), Pb1-xLaxZr1-yTiyO3 (PLZT),
Pb(Mg3Nb2/3)O3-PbTiO3 (PMN-PT), and hafnia (HfO2).


Abstract

ORGANIC/INORGANIC COMPOSITE POROUS FILM FOR A SEPARATOR OF AN
ELECTROCHEMICAL DEVICE, METHOD FOR MANUFACTURING THE SAME
AND ELECTROCHEMICAL DEVICE PREPARED THEREBY
Disclosed is an organic/inorganic composite porous film comprising: (a) inorganic
particles; and (b) a binder polymer coating layer formed partially or totally on surfaces of
the inorganic particles, wherein the inorganic particles are interconnected among
themselves and are fixed by the binder polymer, and interstitial volumes among the
inorganic particles form a micropore structure. A method for manufacturing the same film
and an electrochemical device including the same film are also disclosed. An
electrochemical device comprising the organic/inorganic composite porous film shows
improved safety and quality.

Documents:

00180-kolnp-2007 assignment-1.1.pdf

00180-kolnp-2007 correspondence-1.1.pdf

0180-kolnp-2007-abstract.pdf

0180-kolnp-2007-assignments.pdf

0180-kolnp-2007-claims.pdf

0180-kolnp-2007-correspondence others.pdf

0180-kolnp-2007-description(complete).pdf

0180-kolnp-2007-drawings.pdf

0180-kolnp-2007-form-1.pdf

0180-kolnp-2007-form-3.pdf

0180-kolnp-2007-form-5.pdf

0180-kolnp-2007-international publication.pdf

0180-kolnp-2007-international search authority report.pdf

0180-kolnp-2007-pct form.pdf

0180-kolnp-2007-priority documents.pdf

180-KOLNP-2007-(04-01-2012)--PA-CERTIFIED COPIES.pdf

180-KOLNP-2007-(04-01-2012)-ABSTRACT.pdf

180-KOLNP-2007-(04-01-2012)-AMANDED CLAIMS.pdf

180-KOLNP-2007-(04-01-2012)-DESCRIPTION (COMPLETE).pdf

180-KOLNP-2007-(04-01-2012)-DRAWINGS.pdf

180-KOLNP-2007-(04-01-2012)-EXAMINATION REPORT REPLY RECEIVED.pdf

180-KOLNP-2007-(04-01-2012)-FORM-1.pdf

180-KOLNP-2007-(04-01-2012)-FORM-2.pdf

180-KOLNP-2007-(04-01-2012)-FORM-3.pdf

180-KOLNP-2007-(04-01-2012)-OTHER PATENT DOCUMENT-1.pdf

180-KOLNP-2007-(04-01-2012)-OTHER PATENT DOCUMENT.pdf

180-KOLNP-2007-(04-01-2012)-OTHERS.pdf

180-KOLNP-2007-(04-01-2012)-PA-CERTIFIED COPIES.pdf

180-KOLNP-2007-(09-08-2012)-CORRESPONDENCE.pdf

180-KOLNP-2007-(13-02-2012)-CORRESPONDENCE.pdf

180-KOLNP-2007-(18-03-2013)-CORRESPONDENCE.pdf

180-KOLNP-2007-(19-01-2012)-CORRESPONDENCE.pdf

180-KOLNP-2007-(19-01-2012)-ENGLISH TRANSLATION.pdf

180-KOLNP-2007-ASSIGNMENT.pdf

180-KOLNP-2007-CORRESPONDENCE.pdf

180-KOLNP-2007-EXAMINATION REPORT.pdf

180-KOLNP-2007-FORM 18 1.1.pdf

180-kolnp-2007-form 18.pdf

180-KOLNP-2007-FORM 3.pdf

180-KOLNP-2007-FORM 5.pdf

180-KOLNP-2007-GPA.pdf

180-KOLNP-2007-GRANTED-ABSTRACT.pdf

180-KOLNP-2007-GRANTED-CLAIMS.pdf

180-KOLNP-2007-GRANTED-DESCRIPTION (COMPLETE).pdf

180-KOLNP-2007-GRANTED-DRAWINGS.pdf

180-KOLNP-2007-GRANTED-FORM 1.pdf

180-KOLNP-2007-GRANTED-FORM 2.pdf

180-KOLNP-2007-GRANTED-SPECIFICATION.pdf

180-KOLNP-2007-OTHERS.pdf

180-KOLNP-2007-REPLY TO EXAMINATION REPORT.pdf

180-KOLNP-2007-TRANSLATED COPY OF PRIORITY DOCUMENT.pdf

abstract-00180-kolnp-2007.jpg


Patent Number 255784
Indian Patent Application Number 180/KOLNP/2007
PG Journal Number 13/2013
Publication Date 29-Mar-2013
Grant Date 22-Mar-2013
Date of Filing 15-Jan-2007
Name of Patentee LG CHEM, LTD.
Applicant Address 20, YOIDO-DONG, YOUNGDUNGPO-GU, SEOUL, 150-721
Inventors:
# Inventor's Name Inventor's Address
1 YONG, HYUN HANG 145-113, ORYU2-DONG, GURO-GU, SEOUL 152-102
2 KIM,SEOK KOO 211-1203 EXPO APARTMENT JEONMIN-DONG,YUSEONG -GU DAEJEON 305-761
3 AHN,SOON HO 109-1004 ,SAMSUNG HANWOOL APARTMENT,SHINSUNG-DONG YUSEONG-GU,DAEJEON 305-707
4 SUK,JUNG DON 101-15047,HANBIT APARTMENT EOEUN-DONG,YUSEONG-GU DAEJEON 305-333
5 LEE,SANG YOUNG 103-904,EXPO APARTMENT JEONMIN-DONG,YUSEONG -GU DAEJEON 305-761
PCT International Classification Number H01M2/14
PCT International Application Number PCT/KR2005/002674
PCT International Filing date 2005-08-17
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10-2005-0009999 2005-02-03 Republic of Korea
2 10-2004-0070095 2004-09-02 Republic of Korea
3 10-2004-0070096 2004-09-02 Republic of Korea