Battery Separator with Supporting Region for High-Temperature Stability
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Solution Overview
Problem
Conventional battery separators made of polyethylene or polypropylene curl under high temperature operations, leading to inner shorts and thermal runaway due to structural changes and heat accumulation, despite ceramic coatings which do not fully prevent curling and subsequent contact between cathode and anode.
Innovation Solution
An electrical insulator with a separation region and a supporting region is introduced, where the supporting region covers the peripheral of the separation region to enhance structural strength and prevent curling, reducing the likelihood of inner shorts by maintaining separation between the anode and cathode, and is integrated into the battery design with a sealing frame for added protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a polymer separator (polyethylene or polypropylene) is used, then the separator can be manufactured easily and at low cost, but the separator curls under high temperature operations causing inner short
Solution Approach 1:
The patent applies composite materials by combining polymer materials with ceramic materials to create a separator that maintains the ease of manufacturing benefits of polymers while adding the high-temperature stability of ceramics. The composite structure prevents curling at high temperatures while retaining manufacturability.
2Temperature
If a ceramic coated separator is used, then the separator can withstand high temperature operations, but the polymer structure still changes due to heat accumulation causing curling and inner short
Solution Approach 1:
The patent uses composite materials combining polymer and ceramic components, where the ceramic provides high-temperature stability and the polymer provides flexibility and manufacturability. This composite structure prevents the polymer from deforming at high temperatures while maintaining ease of production.
Solution Approach 2:
The patent changes the physical and chemical parameters of the separator by incorporating ceramic materials that maintain structural integrity at high temperatures. The ceramic component does not undergo the same thermal degradation as pure polymer, thus preventing curling and maintaining separation effectiveness.
3Area of stationary object
If the separator size is designed larger than the electrode surface area, then the separator can cover the electrodes, but the separator still curls and causes inner short under high temperature
Solution Approach 1:
The patent uses composite materials with ceramic components that maintain dimensional stability at high temperatures. This prevents the separator from curling even when sized larger than the electrodes, ensuring continuous coverage and preventing inner short.
4Strength
If a supporting region is added to the electrical insulator, then the structural strength is improved and curling is prevented, but the device complexity increases
Solution Approach 1:
The patent segments the electrical insulator into distinct functional regions: a separation region for electrical isolation and a supporting region for structural reinforcement. This segmentation allows each region to be optimized for its specific function while working together as an integrated component.
Solution Approach 2:
The patent applies local quality by providing structural support only where needed - at the peripheral edges of the separator - rather than uniformly throughout the entire separator. This localized reinforcement prevents curling while minimizing additional complexity and material usage.
Data Source
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AI summary
An electrical insulator and its related battery are disclosed in the present invention. The electrical insulator includes a separation region and a supporting region. The supporting region is disposed and covers the peripheral surface and at least a part of the lateral surface of the separation region. The battery includes the electrical insulator mentioned above. The electrical insulator is disposed between active material layers and contacts with the active material layers directly. The cathode and the anode active material layers are completely electrical isolated because the electrical insulator totally covers at least one active material layer orthographically. Hence, the inner short of the battery may be prevented.