Coated Non-Woven Separator Substrate With Controlled Pore Size
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Solution Overview
Problem
Current non-woven fabric separators for electrochemical cells, such as lithium ion batteries, face limitations due to large pore diameters and mechanical weaknesses, which affect ion permeability and stability, necessitating additional adhesive layers and complex manufacturing processes.
Innovation Solution
A non-woven fabric made from fibers coated with an organic binder polymer compound, with pore diameters ranging from 0.001 to 10 μm, used as a separator substrate in electrochemical cells, eliminating the need for separate adhesive layers and simplifying the manufacturing process through immersion in a polymer compound solution and calendaring under controlled temperature and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-woven fabric is used as separator substrate, then manufacturing cost is reduced, but mechanical strength and pore diameter control are insufficient
Solution Approach 1:
The patent applies composite materials by combining non-woven fabric substrate with polyolefin resin coating layer. The non-woven fabric provides cost advantage and porosity, while the polyolefin coating layer enhances mechanical strength and enables precise pore diameter control (0.03-10 μm). This composite structure resolves the contradiction between low cost and mechanical strength.
2Ease of manufacture
If non-woven fabric is used as separator substrate, then manufacturing cost is reduced, but pore diameter is relatively large affecting ion permeability
Solution Approach 1:
The patent uses parameter changes by controlling the pore diameter of the polyolefin coating layer to be 0.03-10 μm, which is smaller than the substrate pores. By adjusting coating parameters (resin type, coating amount, drying conditions), the effective pore diameter is precisely controlled to optimize ion permeability while maintaining cost advantage of non-woven fabric substrate.
3Strength
If additional adhesive layers are added to improve mechanical properties, then strength is improved, but device complexity and manufacturing process become more complex
Solution Approach 1:
The patent merges the adhesive layer function with the polyolefin coating layer. The coating layer simultaneously provides mechanical strength enhancement, pore diameter control, and adhesive properties for electrode attachment. This consolidation eliminates separate adhesive layers and simplifies the manufacturing process while maintaining improved mechanical properties.
4Manufacturing precision
If pore diameter is reduced to improve ion permeability control, then manufacturing precision is improved, but mechanical strength decreases
Solution Approach 1:
The composite structure of non-woven fabric substrate with polyolefin coating layer resolves this contradiction. The coating layer with controlled small pores (0.03-10 μm) provides precise ion permeability control, while the underlying non-woven fabric substrate maintains overall mechanical strength. The synergistic combination allows small effective pores without sacrificing structural integrity.
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 coated non-woven fabric provides enhanced mechanical properties and improved lithium ion mobility, ensuring stability and simplifying the manufacturing process while maintaining favorable electrochemical performance.
Implementation Method 1
a non-woven fabric made from a fiber coated with an organic binder polymer compound
Implementation Method 2
method of making the non-woven fabric by immersing a spun web fiber in an organic binder polymer compound solution
Data Source
AI summary
The present disclosure relates to a non-woven fabric made from a fiber coated with a binder polymer by spinning a non-woven forming fiber in an organic binder polymer compound solution, an electrochemical cell using the non-woven fabric as a separator substrate, and a method of making the non-woven fabric, and the non-woven fabric has a pore diameter in a range of 0.001 to 10 μm, thereby providing a mechanical property required for a separator while ensuring a favorable movement of a lithium ion, and in the use of the non-woven fabric as a separator of an electrochemical cell, eliminating a need for a process of applying a separate adhesive layer, resulting in an effect of simplifying a separator manufacturing process.