Glass Composite Battery Separator for Heat-Stable Electrolyte Wetting
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Solution Overview
Problem
Existing battery separators face challenges with mechanical stability at high temperatures, significant shrinkage, poor wetting with electrolytes, and limited participation in electrode reactions, which affect their performance and longevity.
Innovation Solution
A battery separator composite comprising 5-95% glass fibers, 5-95% glass plates with specific compositions, and 0-95% binder, offering enhanced temperature stability, mechanical flexibility, and improved electrolyte wetting, allowing ion participation in electrode processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polymer-based separators are used, then mechanical stability is achieved at low temperatures, but temperature stability deteriorates above 100°C with significant shrinkage
Solution Approach 1:
The patent employs a composite structure combining polymer matrix with glass fiber reinforcements and ceramic coatings. This composite approach allows the separator to maintain mechanical flexibility from the polymer while gaining high-temperature stability from the glass and ceramic components that resist shrinkage and deformation at elevated temperatures.
Solution Approach 2:
The patent modifies the chemical composition parameters of the separator by incorporating specific ratios of glass fibers (5-50 wt%) and ceramic particles (1-20 wt%) into the polymer matrix. These compositional changes enable the material to maintain structural integrity across a broader temperature range while preserving low-temperature mechanical properties.
2Ease of manufacture
If polymer-based separators are used, then ease of manufacture is achieved, but wetting with electrolyte liquid deteriorates
Solution Approach 1:
The patent utilizes a porous structure with controlled pore size distribution (0.01-10 μm) created through phase separation or foam formation during manufacturing. This porous architecture increases the surface area available for electrolyte contact and capillary action, significantly improving wetting performance while maintaining compatibility with standard polymer processing techniques.
3Temperature
If glass-based separators are used, then temperature stability is improved, but mechanical flexibility deteriorates
Solution Approach 1:
The patent applies glass fiber reinforcements and ceramic coatings locally within the polymer matrix rather than using bulk glass materials. This localized approach provides high-temperature stability at specific critical regions while allowing the polymer matrix to maintain overall flexibility and mechanical compliance in other areas.
Solution Approach 2:
The patent uses thin glass fiber mats and flexible ceramic-coated structures embedded in the polymer matrix. These thin-film reinforcements provide thermal stability without creating rigid, brittle structures, maintaining the separator's flexibility needed for battery assembly and operation.
4Temperature
If ceramic-based separators are used, then temperature stability is improved, but weight increases
Solution Approach 1:
The patent employs porous ceramic coatings and hollow glass microsphere reinforcements that provide high-temperature stability with minimal material volume. The porous structure reduces the density of the ceramic components while maintaining their thermal resistance properties, thereby limiting weight increase.
Solution Approach 2:
The patent creates a hybrid composite where lightweight polymer matrix is combined with small quantities of high-performance ceramic and glass components. This composite strategy achieves the required temperature stability using minimal amounts of heavy ceramic material, keeping the overall separator weight low compared to fully ceramic alternatives.
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 high temperature stability, reduced shrinkage, optimized electrolyte wetting, and enhanced cell performance through ion participation, leading to improved battery performance and extended lifespan.
Implementation Method 1
the glass platelets (B) have an average thickness of 0.05 μm to 30 μm... the battery separator has a porosity in the range of 10 to 70% and a total thickness of 0.01 mm to 0.5 mm
Implementation Method 2
a porous, ion-permeable glass disk or a porous, ion-permeable glass ceramic disk, the disk having an average pore size of less than 1 μm
Implementation Method 3
the glass platelets (B) have the following composition: 45 to 55% by weight of SiO2, 38 to 45% by weight of B2O3, 5 to 9% by weight of Na2O... 5 to 9 wt.% Li2O
Implementation Method 4
a composite that contains the following components: (A) 5 to 95% by weight of at least one carrier material consisting of glass fibers... (C) 0 to 95% by weight of at least one binder
Data Source
Figure 1~2
Figure 3~4c
Figure 5~6
AI summary
The present invention relates to a battery separator containing a composite that in turn contains the following components: (A) 5 to 95 wt.-% of at least one carrier material that consists of glass fibers, the carrier material being selected from the group comprising nonwovens, laid scrims, knitted fabrics, woven fabrics and/or mixtures thereof; (B) 5 to 95 wt.-% of at least one glass platelet having an average thickness of 0.05 μm to 30 μm; and (C) 0 to 95 wt.-% of at least one binder; the components (A), (B) and (C) adding up to 100 wt.-% and the battery separator having a porosity in the range of 10 to 70% and a total thickness of 0.01 mm to 0.5 mm. The present invention further relates to methods for producing the battery separator and to the use thereof in a battery.