Nanoporous Battery Separator for Transition Metal Ion Blocking

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Solution Overview

Problem

Existing lithium battery manufacturing processes are slow, complex, and expensive, and they face safety issues due to metal fragments and metal ion migration, particularly with transition metals like manganese, nickel, and cobalt, which reduce battery cycle life.

Innovation Solution

The use of a nanoporous separator with anionic compounds and reinforcement areas, combined with a reusable substrate and high-temperature drying, inhibits metal ion diffusion and enhances mechanical strength, allowing for faster, less expensive production of lithium batteries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional interleaving manufacturing process is used, then battery assembly can be completed, but the process is slow, complex and expensive

Engineering Contradiction:

Improvemanufacturing speedVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges multiple discrete battery layers (electrode layers, separator layers, current collector layers) into a single integrated structure by coating them directly onto a reusable substrate in sequential layers, eliminating the need for traditional interleving processes and reducing manufacturing complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies preliminary coating of electrode materials, separators, and current collectors onto a reusable substrate before final battery assembly, allowing for pre-preparation and streamlining of the manufacturing process to increase productivity

Inventive Principle:

Principle #10Preliminary action

2Productivity

If metal substrates are slit into discrete battery stacks, then battery production can proceed, but metal fragments embed into separator causing short circuits

Engineering Contradiction:

Improvebattery production efficiencyVSAvoidbattery safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent extracts and removes the problematic metal substrate slitting step from the manufacturing process by using a reusable substrate that allows direct coating and assembly, eliminating the source of metal fragment contamination while maintaining production efficiency

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The reusable substrate acts as an intermediary carrier that holds all battery layers during manufacturing, replacing the traditional metal substrate approach and preventing metal fragment generation while enabling efficient battery production

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If transition metals like manganese are used in cathode, then battery cost is reduced, but metal ions migrate through separator reducing cycle life

Engineering Contradiction:

Improvebattery manufacturing costVSAvoidbattery cycle life

Core Design Contradiction:

Ease of manufactureVSDuration of action of stationary object

Solution Approach 1:

The patent converts the harmful effect of metal ion migration by using the anionic compound coating on the separator to actively bind and trap metal ions (such as manganese, nickel, and cobalt) that attempt to migrate from the cathode, transforming the migration problem into a controlled binding process that extends battery cycle life while maintaining cost-effective transition metal cathodes

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 approach reduces production costs, improves safety by preventing short circuits, and extends battery cycle life by controlling metal migration, while maintaining high ionic conductivity.

Implementation Method 1

the separator comprises an anionic compound... inhibits metal ion diffusion

Methodology Applied

Scientific EffectIon Exchange: Ion Exchange

Implementation Method 2

anionic compound... inhibits metal ion diffusion

Methodology Applied

Scientific EffectElectrostatic Repulsion: Electrostatics

Implementation Method 3

the photosensitizer is complexed to the inorganic oxide... absorption of photons by the photosensitizer... polymer formed by the absorption of photons

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 4

coating the inorganic oxide, the release coating, the electrode, and the current collector onto the substrate

Methodology Applied

Scientific EffectPhysical Vapour Deposition: Physical Vapour Deposition

Implementation Method 5

coating the inorganic oxide, the release coating, the electrode, and the current collector onto the substrate

Methodology Applied

Scientific EffectChemical Vapour Deposition: Chemical Vapour Deposition

Implementation Method 6

high-temperature drying

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20260094936A1Nanoporous separators for batteries and related manufacturing methods

Publication Date: 2026.04.02 LG ENERGY SOLUTION LTD

AI summary

Provided is a lithium battery, wherein the battery comprises an anode, a cathode, wherein the cathode comprises one or more transition metals, an electrolyte, and a porous separator interposed between the cathode and anode, wherein the separator comprises an anionic compound. Also provided are methods of manufacturing such batteries.