Functional fabric obtained by recycling separator for secondary battery, and method for manufacturing same
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Solution Overview
Problem
The recycling of discarded secondary battery separators is not efficiently utilized due to issues with bonding and thermal curing, leading to resource waste and environmental pollution, and existing methods fail to maintain the microporous structure and provide adequate peel strength for functional fabrics.
Innovation Solution
A method involving the use of a hot melt web adhesive made of ethylene vinyl acetate (EVA) to laminate a separator sheet with a fabric sheet at controlled speeds and pressures, maintaining tension, to form a functional fabric with a microporous structure and improved peel strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to bond separator to fabric sheet, then peel strength is improved, but separator becomes hard due to thermal curing
Solution Approach 1:
The patent applies parameter changes by precisely controlling bonding temperature (40-60°C) and time (10-30 seconds) to activate adhesive bonding without reaching the thermal curing threshold of the separator material. This parameter optimization enables sufficient peel strength while preventing thermal curing-induced hardness.
Solution Approach 2:
The patent introduces an adhesive layer as an intermediary substance between the separator and fabric sheet. This adhesive mediator provides the necessary bonding strength without requiring direct thermal contact that would cause separator hardening, thus resolving the contradiction between peel strength and thermal curing effects.
2Strength
If heat is excessively supplied in bonding process, then adhesive bonding is improved, but separator becomes hard due to thermal curing
Solution Approach 1:
The patent optimizes bonding temperature parameters to a specific range (40-60°C) that is sufficient for adhesive activation but remains below the thermal curing point of the separator. This precise parameter control achieves strong bonding while avoiding excessive temperature effects.
Solution Approach 2:
The patent applies partial action by providing just enough heat to activate the adhesive bonding without excessive heat supply that would trigger thermal curing. The bonding temperature is carefully controlled to be sufficient for adhesion but insufficient for curing, resolving the contradiction between bonding strength and temperature control.
3Object-generated harmful factors
If separator is recycled without chemical process, then environmental pollution is reduced, but bonding and thermal curing issues remain
Solution Approach 1:
The patent uses an adhesive intermediary to enable reliable bonding of recycled separators to fabric sheets without chemical modification of the separator. This approach maintains the environmental benefits of simple recycling while achieving sufficient fabric functionality through the adhesive mediator.
Solution Approach 2:
The patent optimizes bonding parameters (temperature 40-60°C, time 10-30 seconds) to ensure reliable fabric functionality is achieved through physical bonding alone, without requiring chemical processes. This parameter optimization proves that simple recycling can produce functional fabrics.
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 method effectively recycles secondary battery separators into functional fabrics with maintained microporous structure and soft touch, preventing thermal curing and ensuring adequate peel strength, enhancing their usability as moisture-permeable and waterproof materials.
Implementation Method 1
use of a hot melt web adhesive made of ethylene vinyl acetate (EVA) to laminate a separator sheet with a fabric sheet
Implementation Method 2
laminate the separator sheet and the fabric sheet at controlled speeds and pressures, maintaining tension
Data Source
AI summary
The present invention relates to a functional fabric manufacturing method and a functional fabric thereby, which relates to a method for manufacturing an upcycle functional fabric, comprising steps of: (a) preparing a separator sheet with a microporous structure discarded due to treatment as defective or overproduction in production processes for manufacturing secondary batteries, (b) interposing an adhesive sheet between the separator sheet and a fabric sheet to be added to the separator sheet, thereby supplying each sheet, (c) laminating the separator sheet and the fabric sheet so that they are bonded by melting of the adhesive sheet, wherein in the step (b), each sheet is supplied to maintain a constant tension, but the separator sheet, the adhesive sheet, and the fabric sheet are all supplied at the same speed, and in the step (c), a stacked structure, in which the separator sheet, the adhesive sheet, and the fabric sheet are stacked in this order, is pressurized in a predetermined temperature atmosphere, and laminated.