Online-Coated Battery Separator for Heat Resistance and Low Complexity
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Solution Overview
Problem
Traditional lithium battery separators face challenges with heat resistance, moisture, porosity, and consistency, leading to safety and performance issues, and the complex coating processes result in low yield and high production costs.
Innovation Solution
A coating process for battery separators involving initial heat setting of a polyolefin membrane, online coating, and heat setting of a coating membrane, with a coating system that includes drying ovens and a coating apparatus for improved heat resistance and bonding performance, simplifying the process and increasing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional composite coating process is used with multiple coating layers, then heat resistance and bonding performance are improved, but production complexity increases and yield decreases
Solution Approach 1:
The patent merges multiple separate coating processes into a single integrated online coating process. The coating apparatus is positioned between drying ovens in the heat setting line, allowing coating slurry to be applied and dried in one continuous operation rather than requiring separate coating and drying lines. This reduces production complexity while maintaining the heat resistance benefits of coated separators.
2Reliability
If coating amount is increased to improve heat resistance and bonding performance, then these properties are enhanced, but internal resistance increases excessively
Solution Approach 1:
The patent optimizes the coating slurry composition and coating parameters to achieve uniform, controlled coating thickness. By adjusting slurry concentration, viscosity, and coating application parameters, the process achieves adequate bonding performance with minimal coating amount, preventing excessive internal resistance while maintaining reliability.
3Ease of manufacture
If traditional coating process is used, then coating can be applied, but thickness consistency and porosity are poor
Solution Approach 1:
The patent replaces traditional mechanical coating methods with an online coating process where coating slurry is applied and dried in situ on the moving separator. This continuous process with controlled slurry delivery and immediate drying in the heat setting line achieves superior thickness uniformity compared to batch coating methods, while maintaining ease of manufacture.
4Productivity
If separator porosity is increased to improve ion transport, then electrochemical performance improves, but heat resistance and structural integrity deteriorate
Solution Approach 1:
The patent applies a coating layer containing inorganic heat-resistant particles on the separator surface. This composite structure maintains the separator's high porosity for ion transport while the coating layer provides enhanced heat resistance and structural integrity, allowing both electrochemical performance and thermal stability to be improved simultaneously.
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 solution enhances heat resistance, moisture, and consistency of the separators, significantly improving safety, cycle performance, and electrochemical performance while reducing production costs and complexity.
Implementation Method 1
initial heat setting of a polyolefin membrane, and heat setting of a coating membrane
Implementation Method 2
online coating of the polyolefin membrane
Data Source
AI summary
The present disclosure relates to the field of lithium battery separators, and aims to provide a battery separator and a coating process thereof, a coating system and a battery. The coating process includes: initial heat setting of a polyolefin membrane, online coating of the polyolefin membrane, and heat setting of a coating membrane. The coating system includes a plurality of drying ovens disposed in a travel route of heat setting of a polyolefin membrane, and a coating apparatus for coating a coating slurry on the polyolefin membrane, which is disposed at a spacing position of adjacent drying ovens. When the online coating flow is disposed before the end of the heat setting of the polyolefin membrane, the polyolefin base membrane and the coating slurry are dried by using the temperature of the heat setting drying oven of the polyolefin membrane.