Coated Lead-Acid Battery Separators for Thin High-Power Cells
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Solution Overview
Problem
Lead acid batteries face challenges such as reduced bending stiffness of separators, leading to manufacturing issues and increased acid stratification, which affects battery performance and lifespan.
Innovation Solution
The development of multilayer or composite microporous membrane battery separators with enhanced oxidation resistance, improved surface conductivity, and increased stiffness, achieved through the application of functionalized, coated, or treated layers on the separators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If separator thickness is reduced to increase battery power and performance, then battery power and performance are improved, but bending stiffness of the separator is substantially reduced leading to manufacturing issues
Solution Approach 1:
The patent applies composite materials by coating the polyolefin separator with a thin layer of oxidation-resistant material (such as metal oxides or ceramic materials). This composite structure allows the separator to maintain reduced thickness for higher power while the coating layer provides the necessary mechanical strength and oxidation resistance that would otherwise require greater thickness.
Solution Approach 2:
The patent applies local quality by providing functional coating layers only on specific surfaces of the separator that contact the electrolyte and electrodes. This localized treatment enhances oxidation resistance and mechanical properties at critical interfaces without adding significant overall thickness, thereby maintaining high power while improving strength where needed.
2Power
If separator thickness is reduced to increase battery power, then battery power is improved, but manufacturing precision is worsened due to increased folds and creases
Solution Approach 1:
The composite structure with coating layers provides enhanced surface stability and controlled flexibility, allowing thin separators to be manufactured with fewer defects while maintaining the thickness reduction needed for high power output.
3Ease of manufacture
If conventional polyethylene separator is used, then manufacturing simplicity is maintained, but oxidation resistance is insufficient leading to reduced battery lifespan
Solution Approach 1:
The patent combines conventional polyolefin separator material with thin coating layers of oxidation-resistant materials. This composite approach maintains the manufacturing simplicity and cost-effectiveness of polyolefin separators while adding the oxidation resistance necessary for extended battery lifespan through relatively simple coating processes.
Solution Approach 2:
The patent changes the surface properties of the separator by applying coating layers with different chemical compositions and oxidation resistance characteristics. This parameter change allows the separator to maintain its original manufacturing simplicity while achieving the required reliability for long-term operation in oxidizing environments.
4Power
If separator thickness is reduced, then battery power is improved, but separator reliability is worsened due to increased oxidation susceptibility
Solution Approach 1:
The composite structure with oxidation-resistant coating layers protects the thin separator from oxidation without requiring increased thickness. This allows the separator to maintain reduced thickness for high power while the coating provides the oxidation barrier necessary for reliability.
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
These improved separators enhance charge acceptance, reduce acid stratification, and extend the cycle life of lead acid batteries, while also improving manufacturing efficiency and reducing rejection rates.
Implementation Method 1
enhanced oxidation resistance
Implementation Method 2
allowing for ionic flow
Data Source
AI summary
In accordance with at least selected embodiments, the present application or invention is directed to novel or improved porous membranes or substrates, separator membranes, separators, composites, electrochemical devices, batteries, methods of making such membranes or substrates, separators, and/or batteries, and/or methods of using such membranes or substrates, separators and/or batteries. In accordance with at least certain embodiments, the present application is directed to novel or improved porous membranes having a coating layer, battery separator membranes having a coating layer, separators, energy storage devices, batteries, including lead acid batteries including such separators, methods of making such membranes, separators, and/or batteries, and/or methods of using such membranes, separators and/or batteries. The disclosed separators and/or batteries have improved charge acceptance, improved surface conductivity, improved oxidation resistance, reduced acid stratification, improved resistance to metal contamination induced oxidation, reduced black residue, improved wettability, and/or improved stiffness.