Hybrid-Coated Battery Separator for Thin High-Energy Cells
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Solution Overview
Problem
Existing separators in rechargeable batteries fail to meet the high-performance requirements of new energy vehicles, aerospace, and heavy machinery, lacking in energy density, ionic conductivity, mechanical strength, and thermal stability, while also failing to effectively manage gas generation and electrolyte retention.
Innovation Solution
A separator with a polymer matrix coated with an organic-inorganic hybrid composite compound, formed by periodically assembling basic units expressed by formula I, providing high energy density, mechanical strength, and thermal stability, and enhancing electrolyte wettability and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional polymer separators are used, then manufacturing simplicity is maintained, but energy density and ionic conductivity are insufficient
Solution Approach 1:
The patent applies composite materials by combining organic polymer matrices with inorganic coating layers containing metal oxides (such as Al2O3, SiO2, TiO2) and ceramic materials. This composite structure achieves high energy density through the synergistic effects of the polymer base and inorganic functional layers, while the layered composite design systematically addresses multiple performance requirements simultaneously.
Solution Approach 2:
The patent utilizes porous materials by creating controlled porous structures in both the polymer matrix and inorganic coating layers. The porous structure with specific pore sizes and distributions enhances ionic conductivity by providing efficient ion transport channels, while maintaining appropriate porosity balances energy density and ion transmission capabilities.
2Quantity of substance
If separator thickness is reduced to increase energy density, then energy density improves, but mechanical strength and thermal stability deteriorate
Solution Approach 1:
The patent applies local quality by creating functionally differentiated zones within the separator structure. The polymer matrix provides baseline mechanical strength, while localized inorganic coating layers with specific compositions and thicknesses are applied to enhance thermal stability and mechanical reinforcement at critical regions, allowing thin overall design without sacrificing strength.
Solution Approach 2:
The composite structure combines thin polymer layers with reinforced inorganic coatings, achieving high energy density through reduced total thickness while the inorganic ceramic and metal oxide components provide exceptional mechanical strength and thermal stability that compensate for the reduced overall separator thickness.
3Ease of operation
If organic polymer coating is applied to improve electrolyte wettability, then wettability improves, but thermal stability and gas suppression are insufficient
Solution Approach 1:
The patent merges multiple functional coating layers with different properties - organic polymer layers provide electrolyte wettability and interface compatibility, while inorganic metal oxide and ceramic layers provide thermal stability and gas suppression. The combined multi-layer structure achieves synergistic effects where each layer contributes its specialized function.
Solution Approach 2:
The porous structure in the coating layers enhances electrolyte penetration and wettability through capillary action, while the porous inorganic materials simultaneously provide thermal management through controlled porosity that allows heat dissipation and prevents gas accumulation through appropriate pore size distributions.
4Temperature
If inorganic ceramic material is deposited to improve thermal stability, then thermal stability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies parameter changes by optimizing the composition ratios, thickness parameters, and deposition conditions of inorganic ceramic layers. By carefully controlling these parameters, the patent achieves required thermal stability while minimizing material usage and processing complexity, making the manufacturing process more feasible.
Solution Approach 2:
The porous ceramic coating structure provides high thermal stability through the inherent heat resistance of ceramic materials, while the porous architecture reduces material quantity required and improves coating uniformity, thereby simplifying the deposition process and reducing manufacturing complexity compared to dense non-porous coatings.
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 separator significantly improves battery performance by increasing energy density, ionic conductivity, cycling performance, and thermal stability, while reducing gas generation and enhancing electrolyte retention.
Implementation Method 1
the organic-inorganic hybrid composite compound is formed by periodically assembling, along at least one spatial direction, basic units expressed by formula I
Implementation Method 2
excellent electrolyte wettability and retention rate
Implementation Method 3
ions in the battery can pass through the separator to move between the positive electrode and negative electrode
Data Source
AI summary
This application provides a separator, an electrical apparatus including the separator, and preparation methods thereof. The separator includes a coating layer containing an organic-inorganic hybrid composite compound and provides improved performance in a number of aspects, and the organic-inorganic hybrid composite compound is formed by periodically assembling, along at least one spatial direction, basic units expressed by formula I, Lx(MaCb)y·Az. This application further provides a battery and electrical device containing such separator, preparation methods thereof, organic-inorganic hybrid composite compound for improving performance of a separator.