Perforated Continuous Separator for Curved Battery Wrinkling
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Solution Overview
Problem
Batteries with multiple electrode pairs in a flat, rectangular configuration face challenges when shaped into curved forms, as bending can introduce wrinkles in the continuous separator, leading to structural issues and increased damage risk.
Innovation Solution
Incorporating perforations in the folded regions of a continuous separator to reduce wrinkling during the formation of curved batteries, allowing for a more flexible and secure electrode stack configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a continuous separator is used in a flat battery configuration, then manufacturing efficiency is improved, but the separator develops wrinkles and structural issues when the battery is shaped into curved forms
Solution Approach 1:
The continuous separator is segmented by introducing perforations that divide it into multiple sections or zones. These perforations allow different regions of the separator to move independently during bending, preventing the formation of wrinkles while maintaining the overall continuity of the separator structure for efficient manufacturing
Solution Approach 2:
The separator incorporates porous structures through perforations that extend partially or fully through its thickness. These porous features provide flexibility and accommodate deformation during curving processes, enabling the separator to maintain structural integrity while allowing the battery to be shaped into curved forms
2Adaptability or versatility
If the battery is shaped into curved forms, then adaptability to curved devices is improved, but the separator experiences increased stress and damage risk
Solution Approach 1:
By dividing the continuous separator into segmented zones through perforations, each segment can deform independently during curving, reducing stress concentration and preventing catastrophic failure while enabling adaptation to curved device geometries
Solution Approach 2:
The separator's physical parameters are modified by introducing perforations with specific patterns, sizes, and distributions. These parameter changes alter the mechanical properties of the separator, enhancing its flexibility and ability to withstand bending stresses in curved configurations
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 use of perforated continuous separators in curved batteries minimizes the risk of wrinkling and structural damage, enabling a more compact and durable battery design that can fit within curved devices without additional manufacturing steps.
Implementation Method 1
Incorporating perforations in the folded regions of a continuous separator to reduce wrinkling during the formation of curved batteries
Data Source
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AI summary
Examples disclosed herein relate to a continuous separator having perforations to help reduce or prevent wrinkling of the separator when producing curved electrode stacks. One example provides a battery comprising a plurality of discontinuous electrode layers, and a continuous separator separating the discontinuous electrode layers, the continuous separator having perforations extending at least partially through a depth of the continuous separator in a folded region of the continuous separator.