AGM Battery Separator Structure for Sealed-Part Peel Resistance
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Solution Overview
Problem
Existing separators for lead acid batteries face challenges such as impaired electrolyte retention function, peeling issues during cycle life tests, and reduced strength due to the incorporation of organic fibers for bonding purposes.
Innovation Solution
A separator for lead acid batteries is developed using a combination of micro-glass fibers and heat-fusible organic fibers, specifically designed to maintain high electrolyte retention and strength while preventing peeling during bag-making processing and cycle life tests.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heat-fusible organic fibers are incorporated in micro-glass fiber nonwoven fabric to enable joining, then the nonwoven fabric can be joined together by heat sealing, but the electrolyte retention function is impaired
Solution Approach 1:
The patent applies local quality by creating a core-sheath structure where the fiber has different properties in different regions. The core portion contains heat-fusible organic fibers for joining capability, while the sheath portion contains micro-glass fibers for electrolyte retention. This allows each part of the fiber to perform its specific function without compromising the other.
Solution Approach 2:
The patent uses composite materials by combining micro-glass fibers and heat-fusible organic fibers into a single core-sheath fiber structure. This composite approach allows the fiber to simultaneously provide both the joining capability (from organic fibers) and electrolyte retention function (from glass fibers) that would be contradictory if used separately.
2Ease of manufacture
If a large amount of organic material is incorporated to enable sealing, then the nonwoven fabric can be sealed together, but the electrolyte retention function deteriorates
Solution Approach 1:
The core-sheath structure concentrates the heat-fusible organic material in the core portion, limiting its amount to what is necessary for sealing. The sheath portion is dominated by micro-glass fibers that provide electrolyte retention. This local differentiation allows sealing capability without excessive organic material that would harm electrolyte retention.
Solution Approach 2:
The patent changes the structural parameters of the fiber by creating a core-sheath configuration with specific diameter ratios. The core diameter is controlled to be 0.01 to 0.5 times the fiber diameter, ensuring that the organic material content is sufficient for sealing but limited enough to preserve electrolyte retention function.
3Reliability
If micro-glass fiber nonwoven fabric is used for electrolyte retention, then good electrolyte affinity is achieved, but the fabric cannot be joined together by heat sealing
Solution Approach 1:
The micro-glass fibers are concentrated in the sheath portion of the core-sheath fiber, providing excellent electrolyte retention and affinity where needed. The core portion contains heat-fusible organic fibers that provide joining capability. This spatial separation of functions within the single fiber resolves the contradiction between electrolyte retention and joinability.
4Reliability
If glass fiber material is used, then electrolyte retention function is achieved, but the material is brittle and susceptible to damage such as folding or cracking
Solution Approach 1:
The core-sheath fiber combines brittle micro-glass fibers in the sheath with flexible heat-fusible organic fibers in the core. The organic core acts as a flexible matrix that binds the glass fibers, preventing them from being brittle and susceptible to folding or cracking while maintaining the electrolyte retention function of the glass fibers.
Solution Approach 2:
The patent changes the mechanical properties of the fiber composite by controlling the core-to-sheath diameter ratio and the types of materials used. The organic core provides flexibility and damage resistance, while the glass fiber sheath provides electrolyte retention, achieving a balance between brittleness prevention and functional performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed separator achieves high strength and electrolyte retention, preventing peeling during cycle life tests and ensuring stable battery performance, thus addressing the limitations of existing separators.
Implementation Method 1
a method in which the opposing nonwoven fabric pieces are sealed together by heat sealing
Implementation Method 2
a method in which the opposing nonwoven fabric pieces are sealed together by ultrasonic sealing
Implementation Method 3
a nonwoven fabric made of a micro-glass fiber has been used as a separator for a lead acid battery in order to impart an electrolyte retention function
Data Source
AI summary
[Problem] To provide a separator (AGM separator) for a lead acid battery, which has a high strength required for a recent separator for a lead acid battery and has a high electrolyte retention function, and in which peeling of a bag-making processed part (sealed part) does not occur when a cycle life test is performed. [Solution] A separator for a lead acid battery mainly including a micro-glass fiber and a heat-fusible organic fiber, in which when the separator after bag-making processing using ultrasonic sealing is boiled in water for 60 minutes, a peel strength in a sealed part (fused portion) of the separator is 1 N/20 mm or more.