Battery Separator Double-Layer Ends Against Thermal Shrinkage
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Solution Overview
Problem
Secondary batteries face issues with thermal shrinkage and external impact that can lead to short circuits, compromising safety and reliability.
Innovation Solution
Incorporating a double layer structure at the ends of the separator, formed by folding a portion of the separator or attaching an insulating tape, to increase rigidity and prevent thermal shrinkage and damage from external impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-layer separator is used, then the battery structure is simple and manufacturing is easy, but the separator lacks sufficient rigidity and is susceptible to thermal shrinkage and external impact
Solution Approach 1:
The patent merges two separator layers together to form a double-layer separator structure. This combination increases the overall rigidity and dimensional stability of the separator while maintaining the simplicity of using standard separator materials. The two layers work together to resist thermal shrinkage and external impact forces that would affect a single-layer separator.
Solution Approach 2:
The patent employs a composite separator structure consisting of two separator layers bonded together. This composite approach enhances the mechanical strength and thermal stability of the separator without requiring the development of entirely new materials,而是 combining existing separator materials in a configuration that provides superior performance against thermal shrinkage and impact.
2Volume of moving object
If the separator is made thinner to reduce battery volume, then the battery density increases, but the separator becomes more vulnerable to thermal shrinkage and external impact
Solution Approach 1:
By combining two thin separator layers into a double-layer structure, the patent achieves the benefits of using thinner separators (reduced battery volume) while maintaining or even improving the overall reliability. The combined layers provide sufficient rigidity and thermal stability to prevent short circuits, despite each individual layer being thin.
Solution Approach 2:
The composite double-layer separator structure allows the use of thinner individual layers that can be bonded together to create a separator with adequate mechanical strength and thermal resistance. This composite approach enables volume reduction while maintaining the reliability needed to prevent thermal shrinkage-induced short circuits.
3Object-affected harmful factors
If no double layer is added to the separator, then the manufacturing process is simple, but the separator cannot resist thermal shrinkage and external impact
Solution Approach 1:
The patent combines two separator layers with a simple bonding process to create a structure that resists thermal shrinkage and external impact. The manufacturing process involves bonding pre-made separator layers together, which is a straightforward extension of existing separator manufacturing techniques and does not require complex new processes.
Data Source
AI summary
A secondary battery, including a first electrode including a first substrate and a first active material layer on the first substrate, a second electrode including a second substrate and a second active material layer on the second substrate, and a separator between the first active material layer and the second active material layer, wherein the separator includes a double layer at a first end of the separator.