Abstract
Various coating methods for High Purity Alumina (HPA) onto porous polypropylene battery separators were studied. A slurry has been prepared by dispersion of the alumina powder in acetone solvent and Poly(vinylidene fluoride‐co‐hexafluoropropylene) (PVDF‐HFP) as the binder to obtain an excellent adhesion to the membrane. Doctor blade, spin coating, and Electrospin coating techniques have been utilized to coat a thin layer of HPA on the separator that was followed up with calendering step to improve compactness, decrease thickness and enhance adhesion. The effect of HPA particle size, distribution, and the use of a calendering step on coating thickness, compactness, and electrochemical performance were investigated in three HPA sources. The doctor blade technique was found giving the most uniform coating with the best mechanical properties and high‐temperature resistance. The coated separators were incorporated into lithium‐ion coin cells and the effect on the rate capability and long‐term cycling was studied.
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