Cross-linked Resin Insulating Layer for Battery Electrode Safety
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Solution Overview
Problem
Current lithium ion secondary batteries face challenges in producing cost-effective separators with improved load characteristics and charge-discharge cycle performance, as well as safety concerns due to high temperature melting and potential short circuits.
Innovation Solution
A non-aqueous electrolyte secondary battery design featuring an electrode with a material mixture layer and a porous insulating layer containing a cross-linked resin and inorganic particles, where the insulating layer is formed using oligomers and monomers polymerized by energy ray irradiation, and a mixed layer is created at the interface to enhance bonding and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polyethylene-based porous film is used as a separator to ensure shutdown effect, then safety at normal temperatures is improved, but the separator melts at high temperatures causing short circuits
Solution Approach 1:
The patent applies composite materials by combining polyethylene resin with heat-resistant inorganic particles (such as alumina, silica, or boehmite) to form a porous film. This composite structure allows the separator to maintain the shutdown effect of polyethylene while the inorganic particles prevent melting at high temperatures, thus resolving the contradiction between normal temperature safety and heat resistance.
Solution Approach 2:
The patent changes the physical and chemical parameters of the separator by controlling the particle size, distribution, and content of inorganic particles within specific ranges (e.g., inorganic particles comprising 5-80 wt% of the porous film). This parameter optimization ensures both the shutdown function and high-temperature stability are achieved simultaneously.
2Temperature
If ceramic particles are applied to polyethylene microporous film to prevent meltdown, then heat resistance is improved, but production cost increases
Solution Approach 1:
The patent utilizes the inherent porous structure of the polyethylene microporous film as a cost-effective substrate, eliminating the need for complex ceramic coating processes. The inorganic particles are embedded within the porous structure during a single-forming process, simplifying manufacturing while maintaining heat resistance.
Solution Approach 2:
The patent merges the formation of the polyethylene matrix and inorganic particle incorporation into a single simultaneous process, rather than separate steps. This integration reduces production complexity and cost while ensuring uniform distribution of heat-resistant particles throughout the separator structure.
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 solution provides improved load characteristics, charge-discharge cycle performance, and enhanced safety by preventing short circuits and maintaining structural integrity at high temperatures, while also reducing production costs.
Implementation Method 1
The insulating layer contains a resin having a cross-linked structure and inorganic particles... maintaining structural integrity at high temperatures
Implementation Method 2
The insulating layer contains a resin having a cross-linked structure and inorganic particles... preventing short circuits
Implementation Method 3
The insulating layer is formed on the material mixture layer. The insulating layer contains a resin having a cross-linked structure... formed using oligomers and monomers polymerized by energy ray irradiation
Data Source
AI summary
The present invention relates to an electrode for a non-aqueous electrolyte secondary battery, a non-aqueous electrolyte secondary battery using the electrode, and a method for manufacturing the non-aqueous electrolyte secondary battery. The electrode for a non-aqueous electrolyte secondary battery includes a material mixture layer containing an active material and a porous insulating layer. The insulating layer is formed on the material mixture layer. The insulating layer contains a resin having a cross-linked structure and inorganic particles. A mixed layer that includes components of the insulating layer and components of the material mixture layer is provided at the interface between the insulating layer and the material mixture layer.