Mixed-Size Alumina Ceramic Separator for Battery Insulation
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Solution Overview
Problem
Conventional ceramic separators in secondary batteries have reduced insulating properties due to uniform alumina particle sizes, leading to pore compaction issues and potential internal short-circuits during high-temperature conditions.
Innovation Solution
A ceramic separator is formed by mixing two groups of alumina particles with different average diameters (70% smaller and 10-30% larger particles) to improve packing density and pore size, enhancing the insulating properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform alumina particles are used in the ceramic separator, then the manufacturing process is simple, but the insulating properties are reduced due to pore compaction
Solution Approach 1:
The patent applies composite materials by combining alumina particles of different size ranges (0.3-0.7μm and 0.03-0.3μm) to create a ceramic separator with improved insulating properties. The multi-sized particle composite prevents pore compaction while maintaining manufacturing feasibility through a single mixing process.
Solution Approach 2:
The patent applies local quality by creating different pore size distributions in different regions of the ceramic separator structure. The larger particles (0.3-0.7μm) provide structural framework with larger pores, while smaller particles (0.03-0.3μm) fill interstices to create a hierarchical pore structure that prevents compaction and maintains insulation.
2Temperature
If the separator is exposed to high temperature, then the thermal transmission is improved, but the separator may be damaged causing internal short-circuits
Solution Approach 1:
The patent applies parameter changes by utilizing the thermal stability characteristics of ceramic materials and optimizing the particle size distribution. The ceramic separator with multi-sized alumina particles maintains structural integrity at high temperatures, preventing damage and internal short-circuits while allowing necessary thermal transmission.
Solution Approach 2:
The patent applies composite materials by creating a ceramic composite separator with alumina particles of different sizes. This composite structure enhances thermal stability and resistance to high-temperature damage, preventing separator failure and internal short-circuits under thermal stress conditions.
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 improved ceramic separator with mixed particle sizes increases packing density and reduces pore size, thereby enhancing the insulating properties and preventing internal short-circuits, even at high temperatures.
Implementation Method 1
The ceramic filler is formed by mixing first and second groups of ceramic particles, with the first group having a smaller average particle diameter than the second group
Data Source
AI summary
The present invention relates to an electrode assembly and a secondary battery with the same, more particularly to the electrode assembly which includes an anode plate, a cathode plate, and a separator disposed between the anode plate and the cathode plate, wherein the separator includes a ceramic separator including a ceramic filler which is formed by mixing two groups of particles of the same material, but with a different diameter. The particles with the comparatively smaller diameter are disposed between the particles with the comparatively greater diameter.