Battery Insulator with Supporting Region to Prevent Separator Curling
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Solution Overview
Problem
Conventional battery separators made of polyethylene or polypropylene curl under high temperature operations, leading to inner shorts and thermal runaway due to structural changes and material properties, which existing ceramic-coated separators also fail to prevent effectively.
Innovation Solution
An electrical insulator with a separation region and a supporting region is introduced, where the supporting region covers the edge of the separation region to enhance structural strength and prevent curling, reducing the likelihood of inner shorts by adhering to the package structure and electrodes, and using materials like polymer, silicone, or epoxy resin for the supporting region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separator made of polyethylene or polypropylene is used, then the separator can be easily manufactured and assembled, but the separator will curl under high temperature operations causing inner short
Solution Approach 1:
The electrical insulator combines a separation region made of polymer material with a supporting region made of heat-resistant material (ceramic, glass fiber, or metal mesh). This composite structure allows the separator to maintain its manufacturing ease while the heat-resistant supporting region prevents curling under high temperature, thereby resolving the contradiction between ease of manufacture and reliability.
2Temperature
If a ceramic coated separator is used, then the separator can resist high temperature operations, but the polymer structure still changes causing curling and inner short
Solution Approach 1:
The electrical insulator uses a composite structure where the separation region is made of polymer material and the supporting region is made of heat-resistant material such as ceramic, glass fiber, or metal mesh. This composite design provides both temperature resistance and structural stability, preventing the polymer from curling under high temperature while maintaining reliability.
Solution Approach 2:
The electrical insulator applies different material properties to different regions: the separation region uses polymer material for ion conductivity and flexibility, while the supporting region uses heat-resistant material for thermal stability and curl prevention. This local differentiation of material quality resolves the contradiction between temperature resistance and reliability.
3Area of stationary object
If the separation region is made larger to cover the electrodes, then the coverage is improved, but the edge becomes more prone to curling and cracking
Solution Approach 1:
The electrical insulator combines a polymer-based separation region with a heat-resistant supporting region. The supporting region, made of ceramic, glass fiber, or metal mesh, provides enhanced edge strength and curl resistance while allowing the separation region to maintain adequate coverage area, thus resolving the contradiction between coverage area and edge strength.
Solution Approach 2:
The electrical insulator is divided into two functional regions: the separation region for ion conduction and the supporting region for structural reinforcement. This segmentation allows the separation region to be optimized for coverage while the supporting region specifically addresses edge strength and curl prevention.
4Area of stationary object
If the separator is designed with larger size than the electrodes, then complete coverage is achieved, but assembly complexity increases
Solution Approach 1:
The electrical insulator integrates the separation region and supporting region into a single unified component. The supporting region is formed as an integral part of the insulator structure, combining separation and support functions in one piece, thereby maintaining complete electrode coverage while simplifying assembly by eliminating the need for separate support components.
Data Source
AI summary
An electrical insulator and its related battery are provided. The electrical insulator includes a separation region and a supporting region. The supporting region covers the edge of at least one of opposite surfaces of the separation region and at least a part of a lateral surface of the separation region. The battery includes the electrical insulator. The electrical insulator is disposed between cathode and anode active material layers of the battery and contacts the active material layers directly. The cathode and the anode active material layers are completely electrically isolated because the electrical insulator totally covers at least one active material layer. Hence, the inner short of the battery is prevented.