Self-Adhesive Battery Separator Film With Dispersed Binder
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Solution Overview
Problem
Existing battery separator films with polymer binding layers have poor heat resistance, leading to instability and increased thickness, which affects energy density and cycle life, and their preparation process is complex, increasing costs.
Innovation Solution
A self-adhesive separator is developed by dispersing an organic binder in a polymer base film, enhancing mechanical strength and stability, with molecular chain ends exposed for adhesion, allowing for a thinner and more stable separator structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polymer binding layer is sprayed on the surface of a base film to enhance adhesion, then the adhesion between separator and electrode plate is improved, but the heat resistance becomes poor and unstable
Solution Approach 1:
The patent merges the base film and binding layer into a single integrated separator structure where the organic binder is dispersed within the polymer matrix. This eliminates the interface between separate layers and creates a unified structure with both adhesion and heat resistance properties throughout the entire separator.
Solution Approach 2:
The patent uses composite materials by dispersing organic binder molecules within the polymer base film matrix. This composite structure combines the mechanical strength and adhesion properties of the organic binder with the thermal stability of the polymer matrix, achieving both adhesion enhancement and heat resistance.
2Strength
If a polymer binding layer is sprayed on the surface of a base film, then adhesion is enhanced, but the separator thickness increases
Solution Approach 1:
The patent combines the base film and binding layer functions into a single integrated layer, eliminating the need for a separate sprayed binding layer. This integration maintains adhesion performance while reducing the overall separator thickness.
Solution Approach 2:
The organic binder is dispersed locally within the polymer matrix at specific concentrations, providing adhesion enhancement only where needed within the separator structure, rather than adding a uniform thick layer on the surface.
3Strength
If a polymer binding layer is sprayed on the surface of a base film, then adhesion is enhanced, but the preparation process becomes complex and costs increase
Solution Approach 1:
The patent combines the manufacturing steps into a single process where the organic binder is mixed with the polymer base film during film formation. This eliminates the separate spraying step and reduces process complexity while maintaining adhesion enhancement.
Solution Approach 2:
The organic binder is incorporated into the polymer matrix during the film formation process itself, performing the adhesion enhancement function in advance during manufacturing rather than requiring a subsequent spraying step before battery assembly.
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 self-adhesive separator improves energy density and prolongs cycle life while maintaining stability and reducing thermal runaway risk, with a simpler and less costly preparation process.
Implementation Method 1
an organic binder dispersed in the polymer base film
Implementation Method 2
based on the cohesiveness of the organic binder in the material of the polymer base film, the mechanical strength of the polymer base film is enhanced
Implementation Method 3
molecular chain ends of a part of the organic binder are exposed on a surface of the polymer base film
Data Source
AI summary
A separator film comprises a polymer base film and an organic binder dispersed in the polymer base film, and the tail end of the molecular chain of part of the organic binder is exposed out of the surface of the polymer base film. According to the present application, an organic binder is dispersed in a polymer base film material to form a self-adhesive separator film, and the mechanical strength of the polymer base film can be enhanced by using the binding property of the organic binder in the polymer base film material, thereby improving the overall heat resistance and stability of the separator film; additionally, when the organic binder is dispersed in the polymer base film material, the separator film has a smaller thickness than when the organic binder is sprayed on the surface.