Alkaline Manganese Battery Separator with Nanofiber Fusion
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Solution Overview
Problem
The existing separators for alkaline manganese dry batteries and capacitors face challenges in maintaining uniform air permeability, leading to internal short circuits and reduced battery performance due to the separation of cellulose nanofibers in aqueous solvents, which affects their reliability and lifespan.
Innovation Solution
A separator comprising a porous sheet with cellulose nanofibers integrated both internally and on its surface, bonded by a binder component with a specific SP value of 11 to 16, ensuring strong adhesion and retention of air permeability, primarily using vinyl acetate-based resin fibers and polyvinyl alcohol fibers for enhanced compatibility and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cellulose nanofibers are used in a separator to prevent internal short circuits, then reliability is improved, but the nanofibers drop out in aqueous solvents causing uniformity loss
Solution Approach 1:
A porous sheet acts as an intermediary carrier between the cellulose nanofibers and the electrolytic solution. The porous sheet provides structural support and prevents nanofiber dropout while maintaining the desired air permeability characteristics, resolving the contradiction between reliability and compositional stability.
Solution Approach 2:
The separator is constructed as a composite material combining cellulose nanofibers with a porous sheet. This composite structure leverages the high reliability of cellulose nanofibers for short circuit prevention while the porous sheet provides structural stability and uniformity, preventing nanofiber dropout in aqueous solvents.
2Reliability
If a separator with high air permeability resistance is used to prevent internal short circuits, then reliability is improved, but manufacturing uniformity becomes difficult to control
Solution Approach 1:
The air permeability characteristics are controlled by adjusting parameters of the porous sheet such as pore size, porosity, and fiber arrangement. By optimizing these parameters during manufacturing, uniform air permeability can be achieved while maintaining high reliability for short circuit prevention.
3Ease of manufacture
If the separator structure is simplified to reduce complexity, then ease of manufacture is improved, but the ability to maintain uniform air permeability deteriorates
Solution Approach 1:
The use of a porous sheet as the base structure provides inherent uniformity in air permeability through its controlled pore network. This porous material approach simplifies manufacturing compared to creating uniform structures from solid materials, as the porosity can be controlled during sheet formation to ensure consistent air permeability across the separator.
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 provides a separator with improved air permeability uniformity, preventing internal short circuits and maintaining high retention rates, thus enhancing the performance and longevity of alkaline manganese dry batteries and capacitors.
Implementation Method 1
the cellulose nanofibers are combined with the porous sheet by fusion of the binder component
Implementation Method 2
the separator should have a high electrolytic solution absorption property in order to cause a sufficient electromotive reaction
Data Source
AI summary
To provide a separator which has a combination of a preferable air permeability enabling high prevention of internal short circuit and a high retention rate of such an air permeability in an electrolytic solution, and has more improved uniformity of the air permeability.A separator comprising a porous sheet and cellulose nanofibers, wherein the porous sheet comprises a binder component having the SP value of 11 to 16 (cal/cm3)1/2, and the porous sheet has the cellulose nanofibers at the inside and on the surface thereof, and wherein the cellulose nanofibers are combined with the porous sheet by fusion of the binder component.