Silane-Linked Inorganic Separator Layer for Heat-Shrinkage Resistance
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Solution Overview
Problem
Polyolefin-based porous separators exhibit insufficient thermal stability and electrical characteristics due to high-temperature shrinkage, posing safety risks and performance issues in electrochemical devices.
Innovation Solution
A separator with an inorganic particle layer formed on a porous substrate, where the inorganic particles are connected by a hydrolytic condensate of a silane compound, satisfying a specific light transmittance relation and heat shrinkage rate criteria, enhancing thermal stability and electrical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an inorganic particle layer is formed on a polyolefin porous substrate to improve thermal stability, then heat resistance is improved, but heat shrinkage rate decreases insufficiently and electrical resistance characteristics worsen
Solution Approach 1:
The patent applies composite materials by combining polyolefin porous substrate with specific inorganic particles (such as alumina, silica, or boehmite) to create a separator that achieves both improved heat resistance and maintained electrical characteristics. The inorganic particles form a heat-resistant network structure that prevents shrinkage while maintaining porosity for ion conduction.
Solution Approach 2:
The patent utilizes porous materials by maintaining a controlled porosity of 30-80% in the separator structure. The porous inorganic particle layer allows efficient ion conduction between electrodes while the pore structure itself contributes to heat resistance by providing thermal pathways and preventing dense packing that would cause shrinkage.
2Stability of the object's composition
If the inorganic particle layer is made denser to improve heat resistance, then thermal stability improves, but ion conduction efficiency decreases
Solution Approach 1:
The patent employs porous materials with controlled porosity (30-80%) to achieve both thermal stability and ion conduction efficiency. The porous structure provides thermal resistance while maintaining open pathways for ion transport, resolving the contradiction between density for heat resistance and porosity for conduction.
Solution Approach 2:
The patent applies local quality by creating regions with different porosity and inorganic particle distribution. The inorganic particle layer provides localized heat resistance where needed, while maintaining overall porosity for ion conduction. Different zones of the separator can have optimized properties for their specific functions.
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 solution significantly improves heat resistance and electrical characteristics, ensuring the separator maintains integrity and performance at high temperatures, thereby enhancing the safety and efficiency of electrochemical devices.
Implementation Method 1
an inorganic particle layer provided on at least one surface of the porous substrate, wherein the inorganic particles are connected by a hydrolytic condensate of a silane compound
Data Source
AI summary
A separator, a method of manufacturing the separator, and an electrochemical device including the separator with the separator including: a porous substrate; and an inorganic particle layer provided on at least one surface of the porous substrate, wherein the inorganic particle layer includes inorganic particles and a hydrolytic condensate of a silane compound.