Alkaline Battery Separator Burst Index Evaluation
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Solution Overview
Problem
Conventional alkaline dry battery separators evaluated in dry conditions do not accurately reflect their strength when impregnated with an alkaline electrolyte, leading to potential internal short-circuits due to inadequate drop impact resistance.
Innovation Solution
A separator for alkaline dry batteries is evaluated and selected based on a burst index within 2 to 10 kPa/(g/m2) after being impregnated with an alkaline aqueous solution containing 30 to 40% potassium hydroxide, ensuring excellent drop impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the separator is evaluated in dry condition before battery assembly, then the evaluation process is simple and quick, but the strength measurement does not accurately reflect the separator's performance when impregnated with alkaline electrolyte
Solution Approach 1:
The separator is impregnated with alkaline electrolyte solution before strength measurement, simulating its actual operating condition in the battery. This preliminary impregnation action ensures that the strength measurement reflects the separator's true performance when in use, resolving the discrepancy between dry-condition evaluation and wet-condition performance.
2Strength
If the separator has high strength in dry condition, then it appears structurally robust, but it does not necessarily have excellent drop impact resistance when impregnated with alkaline electrolyte
Solution Approach 1:
The evaluation method changes the physical state parameter of the separator from dry to impregnated with alkaline electrolyte solution before measurement. This parameter change ensures that the strength measurement accurately reflects the separator's drop impact resistance in its actual operating condition, rather than measuring its dry strength which does not correlate with wet-condition performance.
3Ease of operation
If the separator strength is measured before battery assembly, then the measurement process is convenient, but the measured strength differs from the strength after battery assembly
Solution Approach 1:
The separator is impregnated with alkaline electrolyte solution and allowed to stand for a specified time before strength measurement. This preliminary action simulates the separator's actual condition after battery assembly, ensuring that the measured strength accurately reflects its performance in the assembled battery state.
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 ensures high reliability of alkaline dry batteries by preventing internal short-circuits and maintaining open circuit voltage, as demonstrated by batteries with burst indices within the specified range showing minimal open circuit voltage drops during drop tests.
Implementation Method 1
the separator impregnated with the alkaline aqueous solution
Data Source
AI summary
An alkaline dry battery having high reliability is provided by using a separator that has excellent drop impact resistance when impregnated with an alkaline electrolyte. In the alkaline dry battery according to the present invention, an electrolyte solution is an alkaline aqueous solution containing 30 to 40% by weight of potassium hydroxide, and a separator impregnated with the alkaline aqueous solution has a burst index within a range of 2 to 10 kPa/(g/m2).