Battery Separator Adhesive Layer Bimodal Particle Distribution
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Solution Overview
Problem
Current mobile phones deplete battery power rapidly, necessitating frequent recharging, and users often lack access to charging devices or power outlets in public places.
Innovation Solution
A portable multiple mobile electronic device charging station with integrated wireless speaker, capable of simultaneously charging up to eight devices via USB ports and featuring removable rechargeable battery packs, retractable charging cords, and compliance with wireless communication protocols like Bluetooth and WiFi, allowing for convenient charging and audio output in public places.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive resin particles of uniform diameter are used in the adhesive layer, then the manufacturing process is simple, but the separator shows high resistance after lamination with electrode
Solution Approach 1:
The adhesive resin particles are segmented into multiple size categories (first adhesive resin particles with diameter of 0.8-3 times the inorganic particles, and second adhesive resin particles with diameter of 0.2-0.6 times the inorganic particles). This segmentation creates a multi-level pore structure that reduces resistance while maintaining adhesion, resolving the contradiction between manufacturing simplicity and post-lamination resistance.
Solution Approach 2:
Different regions of the adhesive layer have different particle size distributions. The first adhesive resin particles (larger size) provide structural framework and adhesion, while the second adhesive resin particles (smaller size) fill gaps and create conductive pathways. This local quality variation optimizes both adhesion strength and electrical conductivity, reducing resistance after lamination.
2Strength
If the coating amount of adhesive resin particles is increased to improve adhesion, then the adhesion between separator and electrode is enhanced, but the resistance of the separator increases
Solution Approach 1:
The invention changes the particle size parameter distribution in the adhesive layer rather than simply increasing the total coating amount. By using a bimodal distribution of adhesive resin particles (first particles: 0.8-3 times inorganic particle diameter, second particles: 0.2-0.6 times inorganic particle diameter), the adhesive layer achieves strong adhesion through the larger particles while the smaller particles create porous pathways that maintain low resistance, thus resolving the contradiction between adhesion strength and resistance.
3Ease of manufacture
If polyolefin-based porous substrate is used as separator, then the manufacturing cost is low and basic separation function is achieved, but the separator shows severe heat shrinking behavior at 100°C or higher causing short-circuit
Solution Approach 1:
The separator uses a composite structure combining polyolefin-based porous substrate with a porous coating layer containing inorganic particles (such as alumina, silica, or titania) and binder polymer. The inorganic particles provide thermal stability and prevent heat shrinking at temperatures of 100°C or higher, while the polyolefin substrate maintains low manufacturing cost and basic separation function. This composite material approach resolves the contradiction between manufacturing simplicity and thermal stability.
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 charging station provides extended battery life for multiple devices, enabling convenient charging and audio output in public places, with removable battery packs and retractable cords facilitating easy replacement and expansion, enhancing user convenience and scalability.
Implementation Method 1
a binder polymer disposed partially or totally on a surface of the inorganic particles, wherein the binder polymer connects and fixes the inorganic particles with each other
Implementation Method 2
an adhesive layer present on a surface of the porous coating layer, and including first adhesive resin particles and second adhesive resin particles
Data Source
AI summary
A network enabled portable charging station for it mobile electronic devices comprising a rectangular shaped housing, one or more removable battery packs, a main charging board, a plurality of interchangeable cord housing cartridges, a wireless speaker, and an adjustable faceplate. The plurality of cord housing cartridges comprising retractable charging cords, each of the retractable charging cords having a USB connector end for connecting to the charge and cell balancing circuit board, and a device connector end for connecting to a mobile electronic device. The faceplate is configured to be retractable or removable from the housing body, and with one or more USB ports for receiving a USB-enabled charging cord, and a plurality of charge ports.