Laser-Patterned Battery Separator for Adhesion and Electrolyte Wetting
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Solution Overview
Problem
Conventional polymer-coated separators in battery cells exhibit poor and uneven adhesion forces due to random distribution of the polymer layer, leading to uneven electrode wetting and mechanical integrity issues, which affect battery performance and cyclability.
Innovation Solution
The use of laser-patterned separators, where a pulse laser modifies the polymer layer to create specific patterns on the surface without altering the underlying ceramic layer, improving adhesion, electrolyte flow, and mechanical integrity, while being an eco-friendly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a random distribution of polymer layer is used on ceramic separator, then the adhesion between electrode and separator is improved, but the adhesion becomes uneven and electrode wetting is poor
Solution Approach 1:
The patent applies local quality by creating distinct patterned regions on the separator surface with different polymer concentrations. The laser treatment generates areas with varying adhesion properties - some regions have enhanced polymer concentration for strong adhesion, while other regions maintain lower concentration for good electrolyte wetting. This spatial variation in local composition resolves the contradiction between achieving strong adhesion and maintaining uniform performance.
2Strength
If polymer layer is fully distributed on ceramic layer, then adhesion is maximized, but electrolyte flow and wetting efficiency are reduced
Solution Approach 1:
The patent segments the polymer distribution into distinct patterned regions rather than using a uniform全覆盖 (full coverage) approach. The laser treatment creates a segmented structure where polymer-rich areas provide adhesion while polymer-poor or patterned channels facilitate electrolyte flow. This segmentation allows simultaneous optimization of both adhesion strength and electrolyte filling efficiency.
3Ease of manufacture
If conventional random polymer coating is used, then manufacturing is simple, but additional chemicals are required and environmental friendliness is reduced
Solution Approach 1:
The patent replaces chemical modification methods with a physical laser treatment process. Instead of using additional chemicals to modify or crosslink the polymer layer, the invention uses laser energy to locally transform the polymer structure and create patterned adhesion regions. This substitution eliminates harmful chemical usage while maintaining manufacturing simplicity and enhancing performance.
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 laser-patterned separators enhance battery assembly, promote efficient electrolyte filling, reduce cell resistance, and improve cyclability, while maintaining adequate adhesion and wettability, thus improving overall battery performance.
Implementation Method 1
an ultra-fast or pulse laser to scan the surface of the randomly-distributed polymer layer to generate a pattern or design into the polymer layer
Data Source
AI summary
Provided are separators for a battery cell comprising a polymer layer having a laser-patterned surface and a ceramic layer. The separators can further include a base layer, and the layers of the separator are provided in the following order: base layer, ceramic layer, and polymer layer. The laser-etching of the polymer layer does not modify the other layers of the separator.