Alkaline Battery Separator Immersion Method
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Solution Overview
Problem
Existing methods for producing alkaline primary batteries face issues with internal short circuits due to the displacement of the gelled negative electrode, which causes leakage and reduces battery performance, and the use of multiple bottom portions in separators leads to increased internal resistance and decreased negative electrode capacity.
Innovation Solution
The method involves injecting a sufficient amount of electrolyte to immerse the lower end of the cylindrical separator portion, preventing inward bending and maintaining the integrity of the separator structure, thereby preventing negative electrode overflow and maintaining the capacity and resistance of the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the lower end of the cylindrical separator portion is left unfixed, then the separator structure is simpler, but the negative electrode may overflow and cause internal short circuit
Solution Approach 1:
The patent applies preliminary anti-action by injecting a specific amount of electrolyte before filling the negative electrode. The electrolyte immerses the lower end of the cylindrical separator portion, creating a preliminary constraint that prevents inward bending during subsequent negative electrode filling. This pre-established countermeasure eliminates the need for complex mechanical fixing structures while ensuring reliability.
2Reliability
If two bottom portions are used in the separator, then negative electrode leakage is prevented, but the internal resistance increases and negative electrode capacity decreases
Solution Approach 1:
The patent extracts the essential function of the second bottom portion (preventing negative electrode leakage) and implements it through a different mechanism. Instead of adding another bottom portion that would reduce negative electrode capacity, the invention uses the electrolyte-immersed lower end of the cylindrical separator portion to achieve the same leakage prevention effect, thereby maintaining maximum negative electrode capacity.
3Shape
If the lower end of the cylindrical separator portion bends inward, then the separator fits tighter, but the negative electrode cannot permeate properly and overflows
Solution Approach 1:
The patent applies preliminary action by immersing the lower end of the cylindrical separator portion in electrolyte before the negative electrode filling process. This preliminary immersion creates a stabilizing effect that prevents inward bending during negative electrode permeation, ensuring proper filling without overflow while maintaining good separator fit.
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
This approach effectively suppresses inward bending of the separator, prevents negative electrode overflow, and maintains the battery's performance by ensuring the correct filling of the negative electrode without increasing internal resistance.
Implementation Method 1
the amount of the electrolyte injected into the separator in step (3) is sufficient to impregnate the positive electrode and the separator and immerse a lower end of the cylindrical portion of the separator in the electrolyte remaining in the separator
Data Source
AI summary
A method for producing an alkaline primary battery includes: (1) forming a cylindrical positive electrode having a hollow; (2) inserting a cylindrical separator with a bottom into the hollow of the positive electrode, the separator including: a wound cylindrical portion; and a bottom portion that is substantially U-shaped in cross-section, the bottom portion covering an opening of the cylindrical portion at a lower end thereof and having an upstanding portion that extends along a lower outer face of the cylindrical portion; and (3) injecting an electrolyte into the separator. The amount of the electrolyte injected into the separator in the step (3) is sufficient to impregnate the positive electrode and the separator and immerse a lower end of the cylindrical portion of the separator in the electrolyte remaining in the separator, thereby bringing the lower end of the cylindrical portion into contact with the upstanding portion.