Flexible Battery Separator Sponge for 180 Degree Foldability
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Solution Overview
Problem
Existing flexible batteries are limited by rigid or brittle components, such as ceramic separators, which restrict their ability to be substantially deformed or reshaped, preventing them from achieving an operational bend radius of 180 degrees and thus being foldable without loss of power.
Innovation Solution
A flexible and foldable lithium ion battery is developed using a high-elasticity separator sponge with 80-90% porosity and submicron diameter polymer-based fiber mat, along with metal current collectors and a liquid electrolyte, allowing the battery to maintain electrical power supply even when folded to 180 degrees.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If rigid or brittle components such as ceramic separators are used in flexible batteries, then the battery structure is stable and reliable, but the battery cannot be substantially deformed or reshaped, limiting the bend radius and preventing 180 degree folding
Solution Approach 1:
The patent changes the physical and chemical parameters of the separator material from rigid ceramic to flexible polymer-based sponge with controlled porosity (80-90%). This parameter change enables the separator to undergo large deformations while maintaining its structural integrity and functional properties, resolving the contradiction between flexibility and reliability
Solution Approach 2:
The patent employs a composite structure combining polymer fibers with porous sponge architecture. This composite material achieves both mechanical flexibility for deformation and structural stability for reliability, allowing the battery to be folded to 180 degrees while maintaining operational integrity
2Shape
If the separator is made flexible to enable 180 degree folding, then the battery can be substantially deformed, but the separator must maintain sufficient strength to prevent electrode shorting and electrolyte leakage
Solution Approach 1:
The patent utilizes a porous sponge structure with controlled porosity (80-90%) that provides both flexibility for bending and mechanical strength through the three-dimensional network of polymer fibers. The porous structure allows deformation while the interconnected fiber network maintains puncture resistance to prevent electrode shorting and electrolyte leakage
Solution Approach 2:
The patent employs a thin film separator (5-50 microns thickness) made of flexible polymer material that can be substantially deformed. The thin film structure achieves both the required flexibility for 180 degree bending and sufficient strength through the polymer fiber mat architecture to prevent failure during deformation
3Adaptability or versatility
If thin separator material is used to achieve flexibility, then the battery can be deformed with small bend radius, but the separator must maintain adequate thickness to prevent shorting between electrodes
Solution Approach 1:
The patent uses a thin film separator (5-50 microns) made of flexible polymer material that provides adequate electrode separation while maintaining flexibility. The thin film structure enables the battery to be deformed with small bend radius sufficient for 180 degree folding while the polymer fiber mat architecture ensures reliable electrode separation
Solution Approach 2:
The composite polymer fiber mat structure provides both the thin profile needed for flexibility and the mechanical integrity required for reliable electrode separation. The composite architecture achieves deformability and electrode separation simultaneously
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 battery achieves an operational bend radius of 180 degrees with no interruption in power supply, demonstrating enhanced flexibility, self-recovery properties, and safety by preventing electrolyte leakage during mechanical abuse, such as cutting or penetration.
Implementation Method 1
A liquid electrolyte is absorbed by the separator sponge
Implementation Method 2
a high-elasticity separator sponge having a porosity of approximately 80% to approximately 90%
Data Source
AI summary
A flexible and foldable lithium ion battery is disclosed having an operational bend radius of 180 degrees with no interruption in supply of electrical power. The lithium ion battery includes a high-elasticity separator sponge having a porosity of approximately 70% to approximately 90%. The separator is a polymer-based fiber mat having fibers with a submicron diameter. The separator sponge has a thickness in a range of approximately 5 to 50 microns, an air permeability of approximately 100 to approximately 300 s/100 ml, and a puncture resistance of approximately 350 to approximately 950 N. First and second electrodes are disposed on either side of the separator sponge and include active materials positioned on thin metal current collectors. A liquid electrolyte is absorbed by the separator sponge. The battery may be folded upon itself without loss of power.