Porous-Coated Battery Separator for Corner Electrolyte Infiltration
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Solution Overview
Problem
Electrochemical devices, such as batteries, experience corner purple/black spots due to inadequate electrolyte infiltration at the interface gaps, particularly at the corners, leading to performance issues during charge-discharge cycling.
Innovation Solution
A separator with a porous substrate and a porous coating containing polymer particles of specific size ranges (5 μm to 14 μm) is used, creating a buffer to increase interface gaps and enhance electrolyte infiltration, while the polymer's properties improve adhesion and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separators are used in batteries, then the basic separation function is achieved, but the interface gap at the battery corners is small, leading to poor electrolyte infiltration and corner purple/black spot problems
Solution Approach 1:
The patent applies local quality by creating a porous coating layer with specific polymer particle size distribution (5-14 μm) on the separator surface. This localized structural modification at the separator-corners interface increases the interface gap and improves electrolyte infiltration precisely where corner purple/black spots occur, without changing the overall separator structure.
Solution Approach 2:
The patent utilizes porous materials by incorporating a porous coating layer containing polymer particles with 30-70% porosity on the separator surface. This porous structure creates larger interface gaps at the corners, enabling better electrolyte penetration and preventing corner degradation issues.
2Strength
If polymer particles with larger size (5 μm to 14 μm) are used in the porous coating, then the interface gap at corners is increased and adhesion is improved, but the manufacturing precision requirement increases
Solution Approach 1:
The patent applies parameter changes by specifying a particular polymer particle size range (5-14 μm) and controlling the number density (100-180 particles per 130 μm×100 μm region). These parameter specifications optimize both adhesion force and manufacturing feasibility, balancing performance requirements with production capabilities.
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 effectively alleviates corner purple/black spots by ensuring good electrolyte infiltration and adhesion between electrodes, improving the structural stability and packaging performance of electrochemical devices.
Implementation Method 1
the large particle size (maximum diameter in range of 5 μm to 14 μm) polymers in the separator act as a buffer and create a gap at the corners of the electrochemical device, thereby increasing the interface gap at the corners of the electrochemical device. Thus, for the electrochemical device, the electrolyte at the corner interfaces can achieve good infiltration
Implementation Method 2
the large particle size polymer particles used in this application have a lower softening point, making it easier to play a bonding role in the electrochemical device, increasing the adhesion force between the separator and the positive electrode or negative electrode
Data Source
AI summary
A separator includes a porous substrate and a porous coating disposed on at least one surface of the porous substrate, the porous coating includes a polymer, and the polymer includes polymer particles. In a 130 μm×100 μm region on a surface of the porous coating, the number of the polymer particles with a maximum diameter in a range of 5 μm to 14 μm is 100 to 180. The separator has large-particle size polymer that can increase the interface gap at the corners of the electrochemical device. Thus, for the electrochemical device, the electrolyte at the corner interfaces can achieve good infiltration during the charge-discharge cycling process, effectively alleviating the corner purple/black spot problem of the electrochemical device.