Microporous Polymer Separator for High-Power Battery
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Solution Overview
Problem
Conventional microporous polymers have limited porosity, which restricts their effectiveness in applications such as battery separators, where high porosity and ionic conductivity are required for enhanced power and longevity.
Innovation Solution
A microporous polymer with a Gurley air permeability flow rate of 4 seconds or less per mL of air flow per 25 microns of thickness per square inch is developed, comprising a bulk matrix with micropores extending from one surface to another, using a polymer solution with high and low surface tension liquids to create a non-wetting gel phase, resulting in a polymer with high porosity and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional microporous polymer manufacturing methods are used, then the polymer can be produced with basic structural integrity, but the porosity is limited and insufficient for high-performance applications
Solution Approach 1:
The patent employs porogenic agents (such as salts, beads, or bubbles) that are incorporated into the polymer matrix and then removed to create controlled porous structures. This principle directly addresses the contradiction by providing a systematic method to generate high porosity while maintaining structural integrity through the controlled removal of porogenic materials, leaving behind a stable porous framework.
Solution Approach 2:
The patent utilizes phase separation processes where temperature, concentration, and solvent composition parameters are adjusted to control pore formation. By changing these parameters during manufacturing, the polymer transitions between different phases to create the desired porous structure, achieving both high porosity and mechanical strength through controlled parameter optimization.
2Reliability
If porosity is increased to improve ionic conductivity, then battery power and life are enhanced, but mechanical properties may deteriorate
Solution Approach 1:
The patent creates composite porous structures by combining polymer matrices with porous-forming agents and potentially reinforcing materials. This composite approach allows the polymer to achieve high porosity for ionic conductivity while the composite structure itself provides the necessary mechanical strength, resolving the contradiction between these two properties.
Solution Approach 2:
The patent implements local quality by creating regions of different porosity and density within the polymer structure. Areas with higher porosity provide ionic conductivity pathways, while regions with denser polymer concentration maintain mechanical strength, allowing both requirements to be satisfied simultaneously through spatial differentiation of material properties.
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 resulting microporous polymer exhibits high porosity, mechanical strength, and ionic conductivity, making it suitable for high-power battery applications with improved battery life and performance.
Implementation Method 1
using a polymer solution with high and low surface tension liquids to create a non-wetting gel phase
Implementation Method 2
produce a film of gelled polymer from the layer of polymer solution under conditions sufficient to provide a non-wetting, high surface tension solution within the layer of polymer solution
Implementation Method 3
a plurality of micropores extending from the first surface through the bulk matrix and to the second surface thereby providing a fluid communication between the first and second surfaces
Implementation Method 4
The pores of the separator are filled with an ionically conductive electrolyte and allow migration of electrolyte from one electrode to another
Implementation Method 5
removing the liquid from the film of gelled polymer under conditions sufficient to produce the microporous polymer
Data Source
AI summary
The present invention provides microporous polymers and methods for producing and using the same. In particular, microporous polymers of the present invention are highly porous as indicated by a Gurley air permeability flow rate of about 4 seconds or less per mL of air flow per 25 micron of microporous polymer thickness per square inch.