Porous Ribbed Battery Separators for Thermal Stability and Diffusion
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Solution Overview
Problem
Existing battery separators with ribs face issues of thermal instability and low electrolyte diffusion, leading to undesirable performance in preventing direct contact between electrodes.
Innovation Solution
A battery separator design featuring a porous layer with ribs made from a polymer and filler, where the ribs exhibit minimal mass loss at high temperatures and promote electrolyte diffusion through their porosity, formed using a method involving passing a fluid through a screen onto the porous layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ribs are added to battery separator to prevent direct contact between electrodes, then electrode separation is improved, but thermal stability deteriorates
Solution Approach 1:
The ribs are constructed from composite materials consisting of polymer matrix combined with heat-stabilizing additives such as metal oxides (alumina, silica) or flame-retardant compounds. This composite structure maintains the mechanical function of electrode separation while providing thermal stability at elevated temperatures.
Solution Approach 2:
The ribs are designed with a porous internal structure that allows electrolyte penetration while maintaining structural integrity. The porous architecture reduces the density of the ribs, lowering overall heat capacity and improving thermal response, while the polymer material selection ensures flame resistance and thermal stability.
2Strength
If ribs are made solid to provide structural support, then mechanical strength is improved, but electrolyte diffusion deteriorates
Solution Approach 1:
The ribs incorporate a controlled porous structure with interconnected voids that facilitate electrolyte flow through the rib body. The porosity is optimized to balance mechanical strength requirements with electrolyte diffusion needs, allowing ions to penetrate the rib structure while maintaining sufficient structural support for electrode separation.
Solution Approach 2:
Instead of making ribs completely solid or completely hollow, the invention introduces a third dimension of porosity within the rib structure. This internal porous network provides diffusion pathways for electrolyte while the outer shell and struts maintain mechanical integrity, effectively resolving the contradiction between strength and diffusion.
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 thermal stability and electrolyte diffusion, improving the overall performance of the battery separator by maintaining structural integrity and reducing electrical resistance.
Implementation Method 1
cooling the fluid to form ribs comprising the polymer disposed on the porous layer
Implementation Method 2
cooling the fluid to form ribs
Implementation Method 3
the ribs are porous and the plurality of ribs forms a discrete component of the battery separator
Data Source
AI summary
Battery separators comprising ribs are generally described. In some embodiments, the ribs have one or more features that enhance the performance of the battery separator.