Multilayer Battery Separator Segmentation
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Solution Overview
Problem
The manufacturing process for deep cycle battery separators is lengthy and complex due to their thicker backweb thickness and larger ribs, which increases extraction time and production costs compared to automotive battery separators.
Innovation Solution
A multilayer separator composed of two bonded or welded automotive-sized separator layers, each with a backweb thickness of 5-10 mils and overall thickness of 12-65 mils, reduces extraction time to 45-75 seconds and simplifies the manufacturing process by using polyethylene, PVC, rubber, or phenolic resin materials, and optional additives like ground rubber or sodium sulfate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single thick separator with large ribs is used for deep cycle batteries, then the mechanical strength and separation capability are improved, but the extraction time and manufacturing complexity increase significantly
Solution Approach 1:
The patent divides a single thick separator into multiple thinner separator layers bonded together. Each layer has a backweb and ribs, and the layers are stacked with ribs aligned to form a composite structure that achieves the required mechanical strength and thickness without the extraction time penalty of a single thick separator.
2Reliability
If a single thick separator with large ribs is used for deep cycle batteries, then the separation capability is improved, but the manufacturing complexity and production costs increase
Solution Approach 1:
The separator is segmented into multiple standard automotive separator layers that can be manufactured using existing production lines. This segmentation allows each layer to be produced with conventional equipment and processes, reducing overall manufacturing complexity despite the increased number of components.
Solution Approach 2:
The patent creates a composite separator structure by bonding multiple polyethylene separator layers together. This composite approach combines the advantages of standardized automotive separator manufacturing with the performance requirements of deep cycle batteries, simplifying production while maintaining separation capability.
3Loss of time
If thinner automotive separators are used, then the extraction time is reduced, but the overall thickness and mechanical strength are insufficient for deep cycle batteries
Solution Approach 1:
Instead of using one thick separator that requires long extraction time, the patent uses multiple thin separator layers stacked together. The cumulative thickness of the bonded layers achieves the required overall thickness for deep cycle batteries while maintaining the short extraction time characteristic of thin automotive separators.
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 multilayer separator reduces extraction time by up to ⅔, increases stiffness, and decreases rib mass while minimizing pinholes, offering improved performance and cost-effectiveness compared to standard deep cycle battery separators.
Implementation Method 1
The layers may be bonded or welded together
Data Source
AI summary
A multilayer deep cycle battery separator comprising at least two layers of an automotive-sized separator bonded or welded together. The automotive-sized separator layers include a backweb having a backweb thickness between 6 to 10 mils, an overall thickness of between 25 to 65 mils, and a rib base width of between 20 to 35 mils. The automotive-sized separator layers also have an extraction time of between 45 to 75 seconds, thereby providing an overall extraction time of less than a standard deep cycle battery separator.