Ceramic Separator Coating for Tensile Strength and Thermal Safety
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Solution Overview
Problem
Ceramic separators used in electrochemical devices face challenges with low tensile strength, leading to assembly defects and potential short circuits, despite offering high thermal safety.
Innovation Solution
A porous composite ceramic separator is developed with a porous ceramic separator substrate and a coating layer comprising a mixture of binder polymer particles and staple fibers, enhancing tensile strength and preventing short circuits during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic separators comprising inorganic particles are used to achieve high thermal safety, then thermal safety is improved, but tensile strength deteriorates
Solution Approach 1:
The patent applies composite materials by combining ceramic inorganic particles with a polymer coating layer. The ceramic substrate provides thermal safety while the polymer coating layer restores tensile strength. This composite structure allows both materials to contribute their respective advantages, resolving the contradiction between thermal safety and mechanical strength.
Solution Approach 2:
The patent applies local quality by differentiating the properties of different regions of the separator. The inner ceramic substrate region provides thermal safety, while the outer polymer coating region provides tensile strength. Each region is optimized for its specific function, allowing the overall structure to overcome the limitations of using either material alone.
2Reliability
If ceramic separators are used to prevent polymer melting and thermal runaway, then thermal safety is improved, but assembly characteristics deteriorate due to low tensile strength
Solution Approach 1:
The composite structure of ceramic substrate with polymer coating enables both thermal safety and good assembly characteristics. The polymer coating layer provides the necessary tensile strength for handling and assembly operations, while the ceramic substrate maintains thermal safety, thus resolving the contradiction between reliability and ease of manufacture.
3Ease of manufacture
If polymer separator substrates are used to achieve ease of pore formation and good chemical resistance, then ease of manufacture is improved, but thermal safety deteriorates due to shrinkage and melting at high temperature
Solution Approach 1:
The patent applies local quality by assigning different functions to different regions. The polymer coating layer on the surface provides chemical resistance and facilitates pore formation, while the inner ceramic substrate provides thermal safety. This spatial differentiation of properties resolves the contradiction between ease of manufacture and thermal safety.
Data Source
AI summary
A porous composite ceramic separator including a porous ceramic separator substrate including inorganic particles and a binder polymer, where the binder polymer binds and interconnects the inorganic particles; and a coating layer on at least one surface of the porous ceramic separator. The coating layer includes a mixture of binder polymer particles and staple fibers. The porous composite ceramic separator has high thermal safety by the use of the porous ceramic separator substrate, can prevent tensile strength decline, and shows good resistance characteristics and assembly characteristics into an electrochemical device.