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Aluminum oxide (Al2O3) films have been investigated for use in various applications, and numerous deposition techniques have been reported. The spray synthesis method has the advantage of forming a thin layer of crystal at low temperatures using the appropriate precursors. A precursor prepared by diluting Methylaluminoxane with N-methyl pyrrolidone was sprayed onto a porous membrane while varying conditions such as the substrate temperature, feeding speed, and spray amount. The solution penetrated the film during spray application, and the ultra-thin layers deposited on the side wall of the internal pores were observed using a cross-sectional transmission electron microscope (XTEM). The lattice image obtained using the TEM and the composition analysis conducted using a scanning TEM and an energy-dispersive X-ray spectroscope suggest that this thin layer is a layer of Al2O3. The formation of Al2O3 occurred at lower temperatures than in previous reports. This is a major advantage for applications with low-melting-point materials. The most suitable spraying conditions were determined based on the state of deposition on the surface and inside the membrane. These conditions were applied to a three-layer separator for lithium-ion batteries and their effect on thermal stability was investigated. Through heating experiments and XRD analysis, it was confirmed that the shrinkage and melting of the separator are suppressed by spraying. This process can be expected to have wide applications in low-melting-point materials such as polyolefin. [ABSTRACT FROM AUTHOR]

Depositions are conducted on monolayer porous membrane at 50 °C by spray pyrolysis using methylaluminoxanes diluted with N‐methylpyrrolidone. The solution penetrates the film during spraying and the ultra‐thin layers are deposited on the side wall of internal pores. It is suggested that these layers are fine polycrystalline of Al2O3. In the obtained film, most of the pores are exposed on the surface and there is no increase in film thickness. Further, the ionic conductivity is the same as that of the received film, and the thermal stability is improved. This method can be an effective technique for improving the function of the separator used in the lithium‐ion batteries. [ABSTRACT FROM AUTHOR]