Separator Intermediate Layer for Battery Safety and Productivity
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Solution Overview
Problem
Conventional methods for manufacturing non-aqueous electrolyte secondary batteries require complex processes, such as passing the separator through a poor solvent, to apply a resin layer for safety and functionality, which complicates the manufacturing process.
Innovation Solution
Incorporating an intermediate layer with vinylidene fluoride polymer particles between the electrodes and separator, which can be formed using an aqueous dispersion and dried without the need for a porosification process, simplifying the manufacturing method and enhancing safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin layer is applied to the separator using conventional methods (dissolving resin in solvent, coating, passing through poor solvent, drying), then the separator gains improved safety function and electrolyte infusion capability, but the manufacturing process becomes complex and productivity decreases
Solution Approach 1:
The invention changes the physical state of the resin from dissolved solution to suspended particles in aqueous dispersion. This parameter change eliminates the need for solvent evaporation and poor solvent treatment steps, simplifying the manufacturing process while maintaining the resin layer's safety function and electrolyte infusion capability
Solution Approach 2:
The invention extracts and eliminates the complex solvent handling steps (dissolving in organic solvent, coating, passing through poor solvent, drying) from the manufacturing process. By using aqueous dispersion with polymer particles, only a simple coating and drying step is needed, removing unnecessary process complexity while preserving the functional benefits
2Reliability
If a resin layer is applied to the separator using conventional methods, then the separator gains improved safety function, but the manufacturing process complexity increases
Solution Approach 1:
The invention changes the resin application method from solution-based to particle-based aqueous dispersion. This parameter change reduces manufacturing process complexity by eliminating solvent dissolution, poor solvent treatment, and extended drying steps, while maintaining the safety function through the formed resin layer
Solution Approach 2:
The invention removes the complex steps of dissolving resin in organic solvent, coating, passing through poor solvent, and extended drying from the manufacturing process. By using aqueous dispersion with polymer particles, the process is simplified to coating and drying only, reducing device complexity while preserving safety functionality
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
This approach allows for the production of non-aqueous electrolyte secondary batteries with improved productivity and safety, as the intermediate layer provides electrolyte infusion passages and resistance to oxidation and reduction without the need for complex solvent handling.
Implementation Method 1
the intermediate layer... provides electrolyte infusion passages
Implementation Method 2
coating the separator with the resulting solution or dispersion... and then drying
Data Source
AI summary
An object of the present invention is to provide a structure for a non-aqueous electrolyte secondary battery that can be manufactured without going through a complicated process such as passing through a poor solvent. The structure for a non-aqueous electrolyte secondary battery of the present invention comprises a positive electrode, a separator, and a negative electrode, the structure comprising an intermediate layer formed between the positive electrode and the separator and/or between the negative electrode and the separator and including vinylidene fluoride polymer particles constituting 60 to 100 parts by mass per 100 parts by mass of raw materials that constitute the intermediate layer.