Battery Separator Non-Woven Fiber Structure for Thin High Strength
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Solution Overview
Problem
Existing non-woven fabrics used in batteries face challenges in balancing strength and thickness, where reducing thickness compromises safety and cycle life, while increasing thickness affects energy density.
Innovation Solution
Incorporating structural fibers with circular cross-section and profiled fibers having a perimeter coefficient XL of 1<XL≤5, which enhances adhesion and forms a robust network structure, improving strength while maintaining a thin thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the thickness of the non-woven fabric is reduced, then the energy density of the battery is improved, but the strength of the non-woven fabric deteriorates
Solution Approach 1:
The patent changes the geometric parameters of the fiber cross-section by introducing a perimeter coefficient (XL) that quantifies the compactness of the fiber shape. By controlling XL to be 1<XL≤5, the fiber structure is optimized to achieve higher strength at reduced thickness, resolving the contradiction between energy density improvement and strength deterioration
Solution Approach 2:
The patent employs a composite fiber structure combining circular cross-section fibers and profiled fibers with specific perimeter coefficients. This composite approach creates a synergistic effect where the profiled fibers provide enhanced adhesion and structural integrity, allowing the non-woven fabric to maintain high strength while being thinner for improved energy density
2Strength
If the thickness of the non-woven fabric is increased, then the strength of the non-woven fabric is improved, but the energy density of the battery deteriorates
Solution Approach 1:
Instead of increasing thickness to improve strength, the patent changes the fiber morphology parameters by introducing profiled fibers with controlled perimeter coefficients. This parameter change allows strength enhancement through optimized fiber geometry and adhesion properties without increasing the overall fabric thickness, thereby preserving energy density
3Strength
If the perimeter coefficient of profiled fiber is increased, then the adhesion between fibers is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent establishes a specific parameter range (1<XL≤5) for the perimeter coefficient that balances adhesion improvement with manufacturability. This parameter optimization ensures that the fibers achieve sufficient adhesion enhancement while remaining compatible with existing manufacturing capabilities, avoiding excessive precision requirements
Data Source
AI summary
The present disclosure provides a non-woven fabric, a separator, and a battery. The non-woven fabric includes a structural fiber, and the structural fiber includes a circular cross-section fiber and a profiled fiber; and a cross section of at least part of the profiled fibers has a perimeter coefficient being XL, with 1<XL≤5. The present disclosure can improve the strength of the non-woven fabric while maintaining its relatively small thickness, thereby simultaneously improving the safety, cycle life, energy density and other properties of the battery.