Battery Separator Coating for Sonication-Based Layer Release
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Solution Overview
Problem
Current organic-inorganic composite porous separators face challenges in recycling due to the complexity, cost, and environmental concerns associated with releasing the inorganic particle layer, which affects the physical properties and thermal stability of the recycled product.
Innovation Solution
A separator with an inorganic particle layer that can be easily released using a simple sonication process, where the release rate is 70% or more, and is manufactured using a hydrolytic condensate of a silane compound with a low molecular weight and high polar functional group fraction, applied in a weakly acidic atmosphere, enhancing heat resistance and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an inorganic particle layer is formed on the porous substrate to improve thermal stability, then heat resistance is improved, but the separator becomes difficult to recycle and the inorganic particle layer is hard to release
Solution Approach 1:
The inorganic particle layer is designed to be easily extracted from the porous substrate through simple water rinsing and sonication processes. The layer can be completely removed without complex procedures, allowing the porous substrate to be recycled while the inorganic particles are separated for other uses.
Solution Approach 2:
The invention changes the binding parameters between the inorganic particle layer and porous substrate by using specific binders with controlled adhesion strength. This allows the layer to remain attached during normal separator operation (providing heat resistance) but detach easily during recycling processes (enabling reuse).
2Ease of operation
If conventional methods are used to release the inorganic particle layer, then the layer can be removed, but the process becomes complicated, costly, and time-consuming
Solution Approach 1:
The inorganic particle layer is designed as a temporary, easily removable component that can be disposed of or separated through simple, inexpensive processes. Instead of using durable, hard-to-remove coatings, the invention employs a layer that can be quickly stripped away using water and ultrasonic vibration, eliminating the need for complex removal equipment.
Solution Approach 2:
The invention replaces complex mechanical or chemical removal systems with a simple ultrasonic sonication process. Instead of using harsh chemicals, high-pressure jets, or mechanical scraping, the release is achieved through acoustic cavitation that gently detaches the inorganic particles from the substrate.
3Ease of operation
If organic solvents are used to release the inorganic particle layer, then the layer can be removed, but organic solvent remains and adversely affects physical properties and causes environmental pollution
Solution Approach 1:
The invention changes the chemical parameter of the release medium from organic solvents to water. This simple parameter change eliminates all the harmful effects associated with organic solvents while maintaining effective release capability. The water-based process leaves no harmful residues on the recycled substrate.
Solution Approach 2:
The invention converts the potential harm of using release agents into a benefit by using water instead of organic solvents. What could have been a harmful process (chemical exposure) becomes a beneficial, environmentally friendly process that improves both recyclability and environmental sustainability.
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 separator achieves high heat resistance, with a TMA melt fracture temperature of 180°C or higher and a heat shrinkage rate of 3% or less, while allowing for easy recycling through a straightforward sonication process, improving thermal stability and reducing environmental impact.
Implementation Method 1
a release rate of the inorganic particle layer represented by the following Formula (1) is 70% or more when measured by immersing the separator in a water tank at room temperature and then subjecting the separator to sonication under conditions of a frequency of 40 kHz, an output of 1,000 W, and an application time of 60 seconds
Data Source
AI summary
The present invention relates to a separator, a method of manufacturing the separator, and an electrochemical device including the separator. According to an exemplary embodiment of the present invention, a separator includes: a porous substrate; and an inorganic particle layer formed on at least one surface of the porous substrate, wherein a release rate of the inorganic particle layer represented by the following Formula (1) is 70% or more when measured by immersing the separator in a water tank at room temperature and then subjecting the separator to sonication under conditions of a frequency of 40 kHz, an output of 1,000 W, and an application time of 60 seconds: wi−wf/wc∗100 wherein wi is a weight of the separator before the sonication, wf is a weight of the separator after the sonication, and wc is a weight of the inorganic particle layer before the sonication.