Nonwoven Fabric Separator for Lead Storage Battery Stratification
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Solution Overview
Problem
Lead storage batteries face challenges in maintaining long cycle life, high capacity, and low resistance due to stratification phenomena caused by concentration differences in sulfuric acid within the battery cells, which existing separators fail to adequately address.
Innovation Solution
A nonwoven fabric separator composed of recycled or synthetic fibers with specific pore diameter and porosity ranges, including ultrafine and thermoplastic resin fiber layers, is developed to enhance ion permeability, chemical stability, and mechanical strength, preventing sulfate ion precipitation and stratification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass fiber is used in the separator to suppress stratification, then sulfate ion adsorption effect is improved, but the separator becomes poor in flexibility and susceptible to shock
Solution Approach 1:
The separator uses a composite structure combining glass fiber nonwoven fabric (for sulfate ion adsorption) with polyolefin nonwoven fabric layers (for flexibility and shock resistance). This composite material approach allows the separator to simultaneously achieve stratification suppression through glass fiber while maintaining mechanical flexibility through the polyolefin layers.
2Reliability
If ultrafine fiber nonwoven fabric is used to control pore diameter, then ion permeability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The separator utilizes ultrafine fiber nonwoven fabric with controlled pore diameters (0.03-10 μm) to achieve high ion permeability. The porous structure allows efficient ion transport while the specific pore size distribution is optimized to balance performance with manufacturing feasibility.
3Duration of action of stationary object
If the separator structure is optimized for long cycle life, then stratification prevention is improved, but battery capacity and output may be compromised
Solution Approach 1:
The separator employs a multi-layer structure where each layer has specific local functions: the glass fiber layer targets sulfate ion adsorption and stratification prevention, the polyolefin layers provide mechanical strength and flexibility, and the ultrafine fiber layer optimizes ion permeability. This local quality differentiation allows the separator to simultaneously achieve long cycle life through stratification control while maintaining high capacity and output through optimized ion transport pathways.
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 effectively prolongs the cycle life of lead storage batteries by maintaining high ion conductivity and preventing stratification, ensuring stable battery performance and low resistance.
Implementation Method 1
the effect of silica on sulfate ion adsorption suppresses stratification
Implementation Method 2
a nonwoven fabric separator for a lead storage battery, characterized in that a relationship between an average pore diameter (D) of the nonwoven fabric separator and a number of pores (N) satisfies the following equation (1)
Data Source
AI summary
A nonwoven fabric separator for a lead storage battery includes a nonwoven fabric configured with regenerated fibers or synthetic fibers.