Solidified, conformable porous composites and related devices, methods, and uses

Abstract

A solidified, conformable porous composite having interconnected pores and containing thermally-expanded polymer microspheres and a particulate filler material is disclosed herein. An energy storage device containing a solidified, conformable porous composite having interconnected pores and comprising thermally-expanded polymer microspheres and particulate filler material is disclosed herein. A method of making a solidified, conformable porous composite in which no solvent is introduced into and extracted from the composite in the formation of pores is disclosed herein.

Claims

1. A solidified porous composite comprising: a thermally-expanded polymer matrix comprising compression and heat-bonded polymer microspheres having been thermally-expanded to fill a fixed volume cavity of a mold, wherein at least a portion of the compression and heat-bonded polymer microspheres are ruptured, the thermally-expanded polymer matrix having solidified and conformed to a shape of the fixed volume cavity; and a particulate filler material distributed throughout the polymer matrix, wherein the solidified porous composite comprises interconnected pores extending through the polymer matrix and a porosity of 30% or more; and wherein the porous composite is free of a mechanical reinforcement material.

2. The solidified porous composite of claim 1, in which the solidified porous composite is electrolyte-wettable and has a porosity range of 30-90%, as determined by water porosity.

3. The solidified porous composite of claim 1, in which the compression and heat-bonded polymer microspheres and the particulate filler material comprise bonded dry powders or a bonded aqueous dispersion.

4. The solidified porous composite of claim 1, in which the particulate filler material comprises an inorganic material.

5. The solidified porous composite of claim 4, in which the inorganic material comprises an inorganic oxide, a carbonate, a hydroxide, alumina, silica, zirconia, titania, mica, boehmite, or mixtures of any of the foregoing.

6. The solidified porous composite of claim 4, in which the inorganic material comprises about 30 wt % to about 90 wt % of the solidified porous composite.

7. The solidified porous composite of claim 4, in which the particulate filler material further comprises an additive.

8. The solidified porous composite of claim 7, in which the additive comprises a hydrogen-evolution inhibitor, electrolyte-soluble pore former, a structure-enhancing agent, a wettability-enhancing agent, a fragrance, or combinations thereof.

9. The solidified porous composite of claim 1, in which the solidified porous composite comprises a sheet having flat major surfaces, patterned major surfaces, or combinations thereof.

10. The solidified porous composite of claim 9, in which the sheet has at least one patterned major surface and has regions with a thickness of about 0.3 mm to about 0.6 mm or about 0.4 mm to about 0.5 mm and has regions with a thickness of about 0.5 mm to about 5 mm or about 1 mm to about 3 mm.

11. A porous composite comprising: a thermally-expanded polymer matrix and a particulate filler material distributed throughout the polymer matrix, wherein the polymer matrix comprises polymer microspheres having been compression and heat-bonded via thermal expansion of the polymer microspheres in a fixed volume cavity of a mold, wherein at least a portion of the compression and heat-bonded polymer microspheres are ruptured, the thermally-expanded polymer matrix having solidified and conformed to a shape of the fixed volume cavity, wherein the porous composite comprises interconnected pores extending through the polymer matrix and a porosity of 30% or more; and wherein the porous composite is a fragrance storage device and comprises a fragrance at least partially occupying the interconnected pores.

12. The solidified porous composite of claim 1, in which the particulate filler material further comprises an additive, wherein the additive comprises a hydrogen-evolution inhibitor, electrolyte-soluble pore former, a structure-enhancing agent, a wettability-enhancing agent, or combinations thereof.

13. A porous composite substantially only comprising: a thermally-expanded polymer matrix substantially only including polymer microspheres, wherein the polymer matrix comprises polymer microspheres having been compression and heat-bonded via thermal expansion of the polymer microspheres in a fixed volume cavity of a mold, wherein at least a portion of the compression and heat-bonded polymer microspheres are ruptured, the thermally-expanded polymer matrix having solidified and conformed to a shape of the fixed volume cavity; and a particulate filler material distributed throughout the polymer matrix; and a fragrance; wherein the porous composite comprises interconnected pores extending through the polymer matrix and a porosity of 30% or more, and wherein the porous composite comprises between 30 wt % and 90 wt % of the particulate filler material; wherein the porous composite is a fragrance storage device including the fragrance at least partially occupying the interconnected pores; and wherein the porous composite is free of a mechanical reinforcement material.

14. The solidified porous composite of claim 1, wherein the solidified porous composite consists of a thermally-expanded polymer matrix consisting of compression and heat-bonded polymer microspheres and the particulate filler material distributed throughout the polymer matrix.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 depicts pictures showing process steps from Example 3.

(2) FIG. 2A depicts SEM fractured horizontal view images for samples obtained from Example 9.

(3) FIG. 2B depicts SEM fractured vertical view images for the same samples as in FIG. 2A.

(4) FIG. 3 depicts pictures showing the single cell from Example 10.

(5) FIG. 4 depicts samples prepared from Example 11.

(6) FIG. 5A depicts SEM images of the top surface of samples obtained from Example 12. FIG. 5B depicts SEM images for cross-sections for the same samples as in FIG. 5A.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(7) A solidified, conformable porous composites having interconnected pores and containing thermally-expanded microspheres and particulate filler material can be made by mixing expandable microspheres with particulate filler material. The microspheres can be in a dry powder or an aqueous dispersion. Likewise, the particulate filler material can be in a dry powder or an aqueous dispersion. The mixture can then be placed in a mold (or other volumetric confined space) and heated for a sufficient duration to bond the materials together. Expansion of the microspheres provides the necessary compression for bonding. The volume of the mold (which dictates pressure as the microspheres expand) and the temperature and duration of heating can be used to rupture at least a portion of the thermally-expanded polymer microspheres by the escape of the encapsulated gas in the microspheres. After expansion, the mold is slowly cooled. The microspheres stay in an expanded state, bonded together. The solidified, conformable porous composite is then removed from the mold. When an aqueous dispersion is present, then the water can be evaporated off as part of the formation process. A mechanical reinforcement material can be placed in the mold prior to heating the mixture. As used herein, “solidified, conformable porous composite” means that the composite is a solid that has conformed to the shape of the volumetric confined space that the expandable microspheres and the particulate filler material were heated in.

(8) The mold (or other volumetric confined space) can be patterned to provide various rib patterns. Additionally, the solidified, conformable porous composites can be further shaped after removal from the mold. The solidified, conformable porous composites can be formed as a sheet or other desired geometry. For example, a sheet can be formed that has at least one patterned major surface and has regions with a thickness of about 0.3 mm to about 0.6 mm or about 0.4 mm to about 0.5 mm and has regions with an thickness of about 0.5 mm to about 5 mm or about 1 mm to about 3 mm.

(9) The same process can be repeated in a cell of a battery or other energy storage device. A free-flowing mixture of expandable microspheres and particulate filler material can be placed between the electrodes of the cell, the cell capped, and then heat applied to the cell. The fixed volume of the cell provides the necessary compression as the microspheres expand. It is not necessary to remove the solidified, conformable porous composites from the cell. Electrolyte can be added directly to the cell after formation of the solidified, conformable porous composite.

(10) The solidified, conformable porous composites (either formed in situ or in a mold) have good contact with electrodes and no leaching from expanded Expancel microspheres in acid has been detected. The solidified, conformable porous composites have good acid-wettability, good porosity, and allow a battery to have high cyclability and recharge capability.

(11) The solidified, conformable porous composites can be used with a number of energy storage devices, such as an alkaline battery or a lead-acid battery. The solidified, conformable porous composite can constitute a separator or a portion thereof.

(12) The particulate filler material of the solidified, conformable porous composites can include an additive. The solidified, conformable porous composites can include additives that beneficially impact energy storage device performance. Preferred additives include a hydrogen-evolution inhibitor, electrolyte-soluble pore former, a structure-enhancing agent, a wettability-enhancing agent, or combinations thereof. Certain additives can perform multiple functions.

(13) Turning now to specific exemplary additives, the electrolyte-soluble pore former dissolves in the electrolyte (typically sulfuric acid for lead acid batteries and aqueous potassium hydroxide for alkaline batteries) after the battery is assembled and the electrolyte is added. Dissolution of the electrolyte-soluble pore former results in an increase in separator porosity, modification to interconnectivity between mutually adjacent pores (i.e., tortuosity) of the separator, and enhanced pore size distribution. The battery can optionally be flushed with fresh electrolyte after dissolution of the electrolyte-soluble pore former. For lead-acid batteries, preferably, the electrolyte-soluble pore former is magnesium hydroxide, magnesium oxide, or a combination thereof. The electrolyte-soluble pore former can include a sulfate of zinc, lithium, aluminum, magnesium, tin, potassium, or sodium. The electrolyte-soluble pore former can also include a carbonate of lithium, magnesium, potassium, or sodium. The electrolyte-soluble pore former can be combined with the inorganic material referenced above that provides electrolyte-wettability for the solidified, conformable porous composites.

(14) The hydrogen-evolution inhibitor can be distributed throughout the pore structure of the solidified, conformable porous composites. Examples of hydrogen-evolution inhibitors include benzaldehyde derivatives, such as vanillin, ortho-anisaldehyde, 2-hydroxybenzaldehyde, 4-methoxybenzaldehyde, 2,4-dimethoxybenzaldehyde, 2,5-dimethoxybenzaldehyde, veratraldehyde (3,4-dimethoxybenzaldehyde), and 2,3,4 trimethoxybenzaldehyde.

(15) The solidified, conformable porous composites can also include additives that are not particulate filler materials, such as a surface active molecule, such as sodium dodecylbenzene sulfonate or sodium dihexyl sulfosuccinate. Other additives for non-energy storage device uses include fragrances.

(16) The ability to form the solidified, conformable porous composites in situ can have manufacturing benefits. For example, the solidified, conformable porous composites can be made during battery assembly. This could facilitate manufacture of a lead-acid battery in a bipolar stack configuration with its attendant benefits in energy density and uniform current density. Other manufacturing benefits of the solidified, conformable porous composites (either formed in situ or in a mold) will be apparent to those skilled in the art.

(17) In addition to separators, the solidified, conformable porous composites could be used in the manufacture of other components of an energy storage device, such as a flame arrestor. Additionally, the solidified, conformable porous composites could be used for non-energy storage device related uses, such as fragrance storage.

EXAMPLES

(18) For each Example, firm and stable solidified, conformable porous composites were formed by mixing dry powders as listed in Table 1.

(19) For Examples 1-9, the well-mixed dry powder was oven heated at the listed temperature for 1 hour in a tightly sealed 4 oz. plastic jar (see FIG. 1) that provided the required compression to the expanding microspheres which led to the bonding of the mixed powder forming a firm and strong solidified, conformable porous composite.

(20) For Example 10, the solidified, conformable porous composite was formed by bonding the listed formulation of mixed dry powders within a single cell consisting of one positive and one negative electrode harvested from a Deka YB16B dry charged motorcycle battery (East Penn Manufacturing Co., Inc.). The cell was capped and placed in an oven to cure at the listed temperature for two hours. The cell showed high cycling and recharge capability.

(21) For Examples 11-48, the well-mixed dry powder formulation listed and a glass fiber mat were pressed between molds with a gasket and heated at the listed temperature under constant compression for 15 minutes. The mold was allowed to cool slowly before removing the sample. The mold plates were designed with grooves in them so that the finished sample had a ribbed surface. The overall thickness of Examples 11-48 ranged from about 0.5 mm to about 3 mm.

(22) The electrical resistance of Example 26 was evaluated using a DC-pulse technique. Samples were soaked in sulfuric acid and then placed in a test bath. The example showed sufficiently low electrical resistance, indicating good electrolyte wettability.

(23) TABLE-US-00001 TABLE 1 Processing Mechanical Mold or Temp. Reinforcement Porosity Ex. # Formulation Shape (° C.) Type (%) 1 5 g of 3:1 Aerosil 200 Fumed Plastic Jar 140 N/A 80 Silica:Expancel 920 DU 120 Powder 2 5 g of 4:1 Aerosil 200 Fumed Plastic Jar 140 N/A 85 Silica:Expancel 920 DU 120 Powder 3 4 g of 3:1 Milled Rhodia Plastic Jar 140 N/A 80 1165 Micropearl Silica:Expancel 920 DU 120 Powder 4 6 g of 3:1 Milled Rhodia Plastic Jar 140 N/A 80 1165 Micropearl Silica:Expancel 920 DU 120 Powder 5 10 g of 4:1 Milled Rhodia Plastic Jar 140 N/A 85 1165 Micropearl Silica:Expancel 920 DU 120 Powder 6 14 g of 3:2 Milled Rhodia Plastic Jar 110 N/A 50 1165 Micropearl Silica:Expancel 031 DU 40 Powder 7 14 g of 3:1 Milled Rhodia Plastic Jar 100 N/A 60 1165 Micropearl Silica:Expancel 031 DU 40 Powder 8 12 g of 3:1 Milled Rhodia Plastic Jar 95 N/A 60 1165 Micropearl Silica:Expancel 031 DU 40 Powder 9 10 g of 3:1 Milled Rhodia Plastic Jar 95 N/A 60 1165 Micropearl Silica:Expancel 031 DU 40 Powder 10 9:1 Unmilled Rhodia 1165 Single Cell 95 N/A 75 Micropearl Silica:Expancel 031 DU 40 Powder 11 6 g of 13:7 Unmilled Rhodia Flat Sheet 90 Glass Fiber 50 1165 Micropearl Silica:Expancel mat 031 DU 40 Powder 12 6 g of 3:1 Unmilled Rhodia Flat Sheet 90 Glass Fiber 60 1165 Micropearl Silica:Expancel mat 031 DU 40 Powder 13 6 g of 4:1 Unmilled Rhodia Flat Sheet 90 Glass Fiber 65 1165 Micropearl Silica:Expancel mat 031 DU 40 Powder 14 6 g of 17:3 Unmilled Rhodia Flat Sheet 90 Glass Fiber 70 1165 Micropearl Silica:Expancel mat 031 DU 40 Powder 15 6 g of 9:1 Unmilled Rhodia Flat Sheet 90 Glass Fiber 75 1165 Micropearl Silica:Expancel mat 031 DU 40 Powder 16 6 g of 2:1:1 Unmilled Rhodia Flat Sheet 90 Glass Fiber 60 1165 Micropearl Silica:Hi- mat Sil ABS Silica:Expancel 031 DU 40 Powder 17 6 g of 2:1:1 Unmilled Rhodia Flat Sheet 90 Glass Fiber 60 1165 Micropearl Silica:Tixosil mat 43 Silica:Expancel 031 DU 40 Powder 18 6 g of 5:3:2 Unmilled Rhodia Flat Sheet 90 Glass Fiber 65 1165 Micropearl Silica:Hi- mat Sil ABS Silica:Expancel 031 DU 40 Powder 19 6 g of 5:3:2 Unmilled Rhodia Flat Sheet 90 Glass Fiber 65 1165 Micropearl Silica:Tixosil mat 43 Silica:Expancel 031 DU 40 Powder 20 6 g of 2:2:1 Unmilled Rhodia Flat Sheet 90 Glass Fiber 65 1165 Micropearl Silica:Hi-Sil mat ABS Silica:Expancel 031 DU 40 Powder 21 6 g of 2:2:1 Unmilled Rhodia Flat Sheet 90 Glass Fiber 65 1165 Micropearl Silica:Tixosil mat 43 Silica:Expancel 031 DU 40 Powder 22 6 g of 16:1:3 Unmilled Flat Sheet 90 Glass Fiber 65 Rhodia 1165 Micropearl mat Silica:Titanium dioxide:Expancel 031 DU 40 Powder 23 6 g of 16:1:3 Unmilled Flat Sheet 90 Glass Fiber 65 Rhodia 1165 Micropearl mat Silica:Carbon black:Expancel 031 DU 40 Powder 24 5 g of 3:7 Unmilled Rhodia Flat Sheet 150 Glass Fiber 45 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder 25 5 g of 1:1 Unmilled Rhodia Flat Sheet 150 Glass Fiber 60 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder 26 5 g of 7:3 Unmilled Rhodia Flat Sheet 150 Glass Fiber 75 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder 27 5 g of 9:1 Unmilled Rhodia Flat Sheet 150 Glass Fiber 90 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder 28 5 g of 6:7:7 Unmilled Rhodia Flat Sheet 150 Glass Fiber 45 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:High Molecular Weight Polyethylene 29 5 g of 2:1:1 Unmilled Rhodia Flat Sheet 150 Glass Fiber 60 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:High Molecular Weight Polyethylene 30 5 g of 14:3:3 Unmilled Flat Sheet 150 Glass Fiber 75 Rhodia 1165 Micropearl mat Silica:Expancel 920 DU 120 Powder:High Molecular Weight Polyethylene 31 5 g of 6:7:7 Unmilled Rhodia Flat Sheet 150 Glass Fiber 45 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:Maleic Anhydride Modified Polypropylene 32 5 g of 2:1:1 Unmilled Rhodia Flat Sheet 150 Glass Fiber 60 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:Maleic Anhydride Modified Polypropylene 33 5 g of 14:3:3 Unmilled Flat Sheet 150 Glass Fiber 75 Rhodia 1165 Micropearl mat Silica:Expancel 920 DU 120 Powder:Maleic Anhydride Modified Polypropylene 34 5 g of 6:7:7 Unmilled Rhodia Flat Sheet 150 Glass Fiber 45 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:MIPELON ™ Fine Particle Ultra High Molecular Weight Polyethylene Powder 35 5 g of 2:1:1 Unmilled Rhodia Flat Sheet 150 Glass Fiber 60 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:MIPELON ™ Fine Particle Ultra High Molecular Weight Polyethylene Powder 36 5 g of 14:3:3 Unmilled Flat Sheet 150 Glass Fiber 75 Rhodia 1165 Micropearl mat Silica:Expancel 920 DU 120 Powder:MIPELON ™ Fine Particle Ultra High Molecular Weight Polyethylene Powder 37 5 g of 6:7:7 Unmilled Rhodia Flat Sheet 150 Glass Fiber 45 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:Polyethylene Wax 38 5 g of 2:1:1 Unmilled Rhodia Flat Sheet 150 Glass Fiber 60 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:Polyethylene Wax 39 5 g of 14:3:3 Unmilled Flat Sheet 150 Glass Fiber 75 Rhodia 1165 Micropearl mat Silica:Expancel 920 DU 120 Powder:Polyethylene Wax 40 5 g of 6:7:7 Unmilled Rhodia Flat Sheet 150 Glass Fiber 45 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:Secondary Alkyl Sulfonate Surfactant 41 5 g of 2:1:1 Unmilled Rhodia Flat Sheet 150 Glass Fiber 60 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:Secondary Alkyl Sulfonate Surfactant 42 5 g of 14:3:3 Unmilled Flat Sheet 150 Glass Fiber 75 Rhodia 1165 Micropearl mat Silica:Expancel 920 DU 120 Powder:Secondary Alkyl Sulfonate Surfactant 43 5 g of 6:7:7 Unmilled Rhodia Flat Sheet 150 Glass Fiber 45 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:Vanillin 44 5 g of 2:1:1 Unmilled Rhodia Flat Sheet 150 Glass Fiber 60 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:Vanillin 45 5 g of 14:3:3 Unmilled Flat Sheet 150 Glass Fiber 75 Rhodia 1165 Micropearl mat Silica:Expancel 920 DU 120 Powder:Vanillin 46 5 g of 6:7:7 Unmilled Rhodia Flat Sheet 150 Glass Fiber 45 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:Micronized Rubber Powder 47 5 g of 2:1:1 Unmilled Rhodia Flat Sheet 150 Glass Fiber 60 1165 Micropearl Silica:Expancel mat 920 DU 120 Powder:Micronized Rubber Powder 48 5 g of 14:3:3 Unmilled Flat Sheet 150 Glass Fiber 75 Rhodia 1165 Micropearl mat Silica:Expancel 920 DU 120 Powder:Micronized Rubber Powder

(24) It will be apparent to those having skill in the art that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention.