Grooved Battery Separator Core for Winding Alignment
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Solution Overview
Problem
Conventional cores used in battery separator rolls often result in misalignment of the first several layers during winding, leading to reduced production efficiency as the separator needs to be unwound and rewound, causing defects.
Innovation Solution
A core with grooves on its outer peripheral surface, where the grooves are at least 30 μm deep and spaced such that the number of grooves per unit circumference exceeds 0.0025, allowing trapped air to escape and stabilizing the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional core is used for winding the battery separator, then the structure is simple, but misalignment occurs in the first several layers of wound separator
Solution Approach 1:
The core surface is segmented into multiple grooves that divide the winding surface into distinct zones. These grooves segment the air trapping problem into manageable sections, allowing controlled air escape paths while maintaining overall structural simplicity of the core
Solution Approach 2:
The grooves act as intermediary elements between the core surface and the wound separator layers. They provide a mediating structure that facilitates air escape and improves alignment without requiring complex external devices or mechanisms
2Productivity
If the first several layers of separator are wound unstably, then production efficiency decreases due to unwinding and rewinding, but adding complex winding mechanisms increases device complexity
Solution Approach 1:
The grooves are pre-formed on the core surface before winding begins. This preliminary structural preparation creates immediate air escape paths that stabilize the first several layers of winding, preventing misalignment before it occurs and eliminating the need for unwinding and rewinding operations
Solution Approach 2:
The core with grooves performs the alignment function autonomously through its built-in groove structure. The grooves self-regulate air escape during the winding process, providing stable winding conditions without requiring external control mechanisms, sensors, or complex winding system modifications
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
This configuration significantly reduces misalignment of wound layers, improving production efficiency by ensuring proper alignment and minimizing defects in the battery separator roll.
Implementation Method 1
the one or more grooves having a depth of 30 μm or greater, and the following condition (1) being satisfied: N/D>0.0025 (1) where D is the outer circumference in mm of the core and N is the number of the one or more grooves in the outer peripheral surface
Data Source
AI summary
A core prevents or reduces misalignment of a battery separator wound around the core. The core has one or more grooves in the outer peripheral surface thereof. The grooves extend substantially in the width direction of the core. The grooves have a depth of 30 μm or greater, and the following condition (1) is satisfied:N/D>0.0025 (1)where D is the outer circumference in mm of the core and N is the number of the grooves in the outer peripheral surface.