Optimized Separator Design for High-Performance Alkaline Cells
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Summary
Problems
Conventional alkaline electrochemical cells have thick separators that occupy significant volume, reducing the space available for active ingredients and leading to decreased performance, especially in smaller cells.
Innovation solutions
A non-conductive, porous separator material with a mean pore size of about 1 micron to 6 microns and air permeability of 0.5 cc/cm2/s to 3.8 cc/cm2/s at 125 Pa is used, allowing for a reduced number of separator wraps and improved performance.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If a non-woven separator sheet is wound multiple times to ensure sufficient separation between electrodes, then reliability of preventing leakage and shorting is improved, but volume of the separator increases, reducing the volume available for active ingredients
Why choose this principle:
The patent changes the pore size parameter of the separator material to a specific range (0.5-5 microns mean pore size) to achieve both effective separation and reduced volume. This parameter optimization allows fewer wraps to be needed while maintaining separation effectiveness.
Principle concept:
If a non-woven separator sheet is wound multiple times to ensure sufficient separation between electrodes, then reliability of preventing leakage and shorting is improved, but volume of the separator increases, reducing the volume available for active ingredients
Why choose this principle:
The patent uses a composite non-woven material structure combining specific fiber types and pore characteristics to achieve high separation efficiency in a thinner profile, reducing the number of wraps needed compared to conventional separators.
Application Domain
Data Source
AI summary:
A non-conductive, porous separator material with a mean pore size of about 1 micron to 6 microns and air permeability of 0.5 cc/cm2/s to 3.8 cc/cm2/s at 125 Pa is used, allowing for a reduced number of separator wraps and improved performance.
Abstract
An alkaline electrochemical cell includes a cathode; a gelled anode having an anode active material and an electrolyte; and a separator disposed between the cathode and the anode; wherein the separator includes a non-conductive, porous material having a mean pore size of about 1 micron to about 5 microns, a maximum pore size of about 19 microns, and an air permeability of about 0.5 cc/cm 2 /s to about 3.8 cc/cm 2 /s at 125 Pa.