Porous Battery Separator Substrate for High-Pressure Lamination Stability
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Solution Overview
Problem
Existing battery separators face issues with deformation and reduced dielectric breakdown voltage under high-pressure lamination conditions, leading to reduced battery performance and increased risk of short circuits.
Innovation Solution
A porous substrate for separators made from polyolefin-based polymers with controlled pore size distribution, porosity, and thickness, combined with a heat-resistant layer, to enhance stability and dielectric breakdown voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high pressure is applied during lamination to improve adhesion, then adhesive strength increases, but separator deformation and pore damage occur
Solution Approach 1:
The patent applies parameter changes by controlling the pore size distribution (FWHM ≤ 4.0 nm) and porosity (30-60 vol%) of the porous substrate to optimize its mechanical properties. This allows the separator to maintain its shape and resist deformation under high-pressure lamination conditions while still achieving adequate adhesion through controlled pore structure rather than relying solely on increasing pressure
Solution Approach 2:
The patent uses composite materials by combining a porous substrate (made of polyolefin-based polymer resin) with a heat-resistant layer to create a multi-layer separator structure. This composite structure provides both the necessary adhesion properties and resistance to high-pressure deformation, as the heat-resistant layer reinforces the porous substrate during lamination
2Strength
If high pressure is applied during lamination to improve adhesion, then adhesive strength increases, but dielectric breakdown voltage decreases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the pore size distribution (FWHM ≤ 4.0 nm) and porosity (30-60 vol%) of the porous substrate. This optimized pore structure maintains dielectric strength and breakdown voltage even under high-pressure lamination conditions, as the uniform fine pore distribution prevents pore collapse and maintains electrical insulation properties
Solution Approach 2:
The patent uses composite materials by combining a porous substrate with a heat-resistant layer to create a separator that maintains both adhesion and dielectric properties. The heat-resistant layer provides structural support that prevents pore damage during high-pressure lamination, thereby preserving dielectric breakdown voltage while achieving adequate adhesion
Data Source
AI summary
The present disclosure relates to a porous substrate for a separator. The porous substrate according to the present disclosure has a small and uniform pore size, thus having excellent physical strength and durability, and can secure a high dielectric breakdown voltage, resulting in a low short-circuit occurrence rate.