Alkaline Battery Separator Structure for Low Resistance and Shielding
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Solution Overview
Problem
Existing separators for alkaline batteries face challenges in achieving high electrolyte solution holding properties, shielding properties, and low resistance simultaneously, leading to issues such as short circuit failures, decreased discharge capacity, and poor storage characteristics due to conflicting requirements for thickness, density, and fiber composition.
Innovation Solution
A separator composed of two fiber layers, fiber layer A with a density of 0.52 to 0.62 g/cm3 and thickness of 25 to 35 μm, and fiber layer B with a density of 0.40 to 0.50 g/cm3 and thickness of 25 to 35 μm, integrated to achieve a total density of 0.45 to 0.57 g/cm3 and thickness of 50 to 70 μm, using 60 to 90% alkali-resistant cellulose fiber and 10 to 40% alkali-resistant synthetic fiber, with controlled CSF values and polyvinyl alcohol resin in layer B for enhanced stability and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the thickness of the separator is decreased to reduce resistance, then the resistance decreases, but the strength, shielding properties, and liquid holding properties deteriorate
Solution Approach 1:
The separator uses a composite structure combining two different fiber layers: a first fiber layer (60-90% alkali-resistant cellulose fiber, 10-40% alkali-resistant synthetic fiber) and a second fiber layer (60-90% alkali-resistant cellulose fiber, 10-40% binder fiber). This composite structure allows the separator to achieve low resistance while maintaining sufficient strength and functional properties through the synergistic combination of different fiber materials with complementary characteristics.
Solution Approach 2:
The separator is divided into two distinct fiber layers with different compositions and functions. The first fiber layer provides structural support and shielding properties, while the second fiber layer optimizes liquid holding and chemical stability. This segmentation allows each layer to be optimized for its specific function, achieving overall performance balance without requiring uniform thickness throughout.
2Reliability
If the density of the separator is increased to improve shielding properties, then the shielding properties improve, but the liquid holding properties and ion conduction worsen
Solution Approach 1:
Different regions of the separator have different densities and compositions optimized for their specific functions. The first fiber layer has higher density (0.52-0.62 g/cm³) for superior shielding properties, while the second fiber layer has lower density (0.40-0.50 g/cm³) for enhanced liquid holding capacity. This local quality differentiation resolves the contradiction by allowing high shielding in critical areas while maintaining overall electrolyte retention.
3Stability of the object's composition
If alkali-resistant synthetic fiber is used to improve chemical stability, then the chemical stability improves, but the liquid holding properties deteriorate
Solution Approach 1:
The separator combines alkali-resistant synthetic fibers (vinylon, nylon, polypropylene) with alkali-resistant cellulose fibers in a composite structure. The synthetic fibers provide chemical stability and dimensional integrity, while the cellulose fibers contribute hydrophilicity and electrolyte solution holding capacity. This composite material approach allows both properties to coexist by leveraging the complementary characteristics of different fiber types.
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 solution provides a separator with excellent strength, dimensional stability, and chemical stability in electrolyte solutions, while maintaining high shielding and liquid holding properties, reducing resistance, and ensuring high capacity and long life of alkaline batteries.
Implementation Method 1
holding properties of the separator... holding an electrolyte solution such as potassium hydroxide
Implementation Method 2
chemical stability does not cause shrinkage and alteration with respect to the electrolyte solution
Data Source
AI summary
A separator for alkaline batteries, which exhibits excellent strength, dimensional stability and chemical stability in an electrolyte solution, while having high shielding properties, high liquid holding properties and low resistance. A separator for alkaline batteries, which is used for the purpose of separating a positive electrode active material and a negative electrode active material from each other, and holding an electrolyte solution, and which is obtained by stacking and integrating a fiber layer A that has a density of 0.52-0.62 g/cm3 and a thickness of 25-35 μm and a fiber layer B that has a density of 0.40-0.50 g/cm3 and a thickness of 25-35 μm, so that the entirety of the separator has a density of 0.45-0.57 g/cm3 and a thickness of 50-70 μm.