Positive Plate Coating Boundary to Prevent Battery Micro-Shorts
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Solution Overview
Problem
Existing methods for forming an insulation protective layer on a positive current collector in rechargeable batteries result in inefficient use of the positive composite material layer due to mixing and overlapping with the insulation protective layer, leading to reduced battery efficiency and potential micro-short circuits.
Innovation Solution
A method involving the simultaneous application of positive composite material paste and insulation protective paste, with pH adjustments using acetic acid to aggregate boehmite particles, ensuring they do not mix, and forming a distinct boundary layer to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If paste for forming the insulation protective layer is applied separately from the positive composite material layer, then the insulation protective layer can be formed effectively, but the number of coating steps and workstations increases, reducing productivity
Solution Approach 1:
The patent combines the coating of positive composite material paste and insulation protective paste into a single simultaneous coating step using one workstation, merging two separate processes into one to improve productivity while maintaining insulation effectiveness
2Stability of the object's composition
If the insulation protective layer and positive composite material layer are applied to partially overlap, then a gap is prevented between layers, but the overlapped portion hampers electrical connection and ion exchange, reducing battery efficiency
Solution Approach 1:
The patent introduces a boundary portion with aggregated insulation particles as an intermediary zone between the insulation protective layer and positive composite material layer. This aggregated boundary acts as a mediator that maintains layer continuity while preventing harmful overlap mixing, allowing electrical connection to proceed through the aggregated region without significant resistance
3Stability of the object's composition
If paste for forming the insulation protective layer and positive composite material layer are mixed, then a uniform coating can be formed, but the positive composite material becomes inefficient due to mixing with insulation material
Solution Approach 1:
The patent applies local quality by creating a distinct boundary portion with aggregated insulation particles at the interface between the insulation protective layer and positive composite material layer. This localized aggregation prevents mixing in the boundary region while maintaining uniform coating elsewhere, preserving the efficiency of positive composite material
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
Enhances battery efficiency by preventing mixing of the composite material and insulation layers, reducing overlap, and minimizing micro-short circuits, thereby improving the overall performance and productivity of rechargeable batteries.
Implementation Method 1
pH adjustments using acetic acid to aggregate boehmite particles
Implementation Method 2
pH adjustments using acetic acid to aggregate boehmite particles, ensuring they do not mix
Data Source
AI summary
A method for manufacturing a positive plate of a rechargeable battery includes producing an insulation protective paste forming an insulation protective layer of the positive plate, the insulation protective paste including insulation particles, a binder, and a solvent and having a pH adjusted corresponding to a zeta potential at which the insulation particles do not aggregate, producing a positive composite material paste forming a positive composite material layer of the positive plate, the positive composite material paste including a positive active material, a conduction support, a binder, and a solvent, and a pH adjuster being added to the positive composite material paste to adjust a pH corresponding to a zeta potential at which the insulation particles aggregate, and simultaneously coating a positive current collector of the positive plate with the positive composite material paste and the insulation protective paste disposed adjacent to an end of the positive composite material paste.