Dual-Layer Separator with Melt-Bonded Adhesive for Battery Heat Resistance
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Solution Overview
Problem
Batteries with a lamination structure of cathode and anode electrodes between two separators face challenges in enhancing heat resistance, as existing solutions do not effectively provide a high melting point separator between the electrodes.
Innovation Solution
A battery structure incorporating a first separator with a low melting point and a second separator with a higher melting point, where the first separator is melted to form an adhesive layer for bonding the two, enhancing heat resistance between the cathode and anode electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separator of high melting point is provided between the cathode electrode and the anode electrode, then heat resistance is enhanced, but device complexity increases due to the need for multiple separators with different melting points
Solution Approach 1:
The separator is divided into two distinct layers: a first separator layer with a lower melting point (e.g., polyolefin-based) and a second separator layer with a higher melting point (e.g., polyamide or polyimide-based). This segmentation allows each layer to perform its specific function - the first layer provides shutdown function at lower temperatures while the second layer maintains structural integrity at higher temperatures, thereby enhancing overall heat resistance without requiring a completely new separator design
Solution Approach 2:
The invention uses a composite structure combining two different separator materials with different thermal properties. The first separator (lower melting point) and second separator (higher melting point) are laminated together to form a composite separator that exhibits both the shutdown characteristic of the first material and the high-temperature stability of the second material, resolving the contradiction between heat resistance and structural simplicity
2Strength
If two separators are pasted together to enhance heat resistance, then bonding strength is improved, but manufacturing precision becomes more difficult due to the need for precise alignment and bonding
Solution Approach 1:
The first separator is designed to serve a dual function: it acts as both a separator and an adhesive layer. When heated during the lamination process, the first separator melts and bonds the second separator to the electrode, eliminating the need for separate adhesive materials. This self-service approach simplifies the manufacturing process and reduces alignment requirements compared to using separate adhesive layers
Solution Approach 2:
The invention utilizes temperature as a control parameter to manage the bonding process. The first separator is selected with a melting point suitable for the bonding temperature, allowing it to transition from a solid separator to a molten adhesive state during lamination, and then re-solidify to form a strong bond. This parameter-based control enables precise bonding without requiring complex alignment mechanisms
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
This configuration effectively provides a high melting point separator between the cathode and anode electrodes, improving heat resistance and preventing shrinkage of the separators when the battery temperature rises.
Implementation Method 1
a first adhesive layer formed by melting a portion of the first separator, and pasting the first separator and the second separator to each other
Data Source
AI summary
A first separator (130) covers a first surface of a cathode electrode (110). The first separator (130) has a melting point of a first temperature. A second separator (140) covers a second surface of the cathode electrode (110). The second separator (140) has a melting point of a second temperature higher than the first temperature. An adhesive layer (132) is formed by melting a portion of the first separator (130). The adhesive layer (132) pastes the first separator (130) and the second separator (140) to each other.