Battery Separator Roll Core Surface for Slippage and Axial Migration
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Solution Overview
Problem
The slippage and axial migration of battery separator material during unwinding and winding processes lead to misalignment and equipment malfunction in battery manufacturing, particularly in 'start-stop' vehicles, due to insufficient friction between the separator material and the core, causing interruptions and damage.
Innovation Solution
Application of friction enhancing materials, such as sandpaper or rubber strips, to the core surface to increase frictional resistance between the core and separator material, preventing slippage while maintaining easy release without adhesive recoil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If friction enhancing materials are applied to the core surface, then slippage prevention is improved, but release difficulty may worsen
Solution Approach 1:
The core surface is divided into different zones with different friction characteristics. The friction enhancing material is applied only to specific areas where slippage prevention is needed, while other areas maintain lower friction to facilitate easy release. This local differentiation resolves the contradiction between preventing slippage during winding and enabling easy release during unwinding.
Solution Approach 2:
The friction characteristics of the core surface are made dynamic rather than static. The friction enhancing material is designed to provide high friction during the winding phase when the separator is being applied to the core, but allows for easy release during the unwinding phase. This dynamic adaptation resolves the contradiction between slippage prevention and release ease.
2Manufacturing precision
If friction enhancing materials are applied to the core surface, then separator material alignment is improved, but manufacturing complexity worsens
Solution Approach 1:
The friction coefficient of the core surface is modified by applying friction enhancing materials, changing the physical parameter of the core-s separator interface. This parameter change improves separator material alignment during winding without requiring complex mechanical alignment systems, thus resolving the contradiction between manufacturing precision and device complexity.
3Strength
If thicker separators are used to improve puncture resistance, then puncture strength is improved, but ionic resistance worsens
Solution Approach 1:
The separator is designed as a composite material structure combining different materials with complementary properties. This composite structure achieves both high puncture resistance and low ionic resistance simultaneously, resolving the contradiction between strength and ionic resistance that would otherwise require sacrificing one parameter for the other.
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 friction enhancing materials reduce the likelihood of separator material migration by up to three times, ensuring smooth unwinding and reducing manufacturing disruptions, thus enhancing the efficiency and reliability of battery assembly.
Implementation Method 1
increase frictional resistance between the core and separator material
Data Source
AI summary
Rolls of battery separator material and related methods are disclosed. A roll of battery separator material includes a core including an outside surface, a separator material rolled around the core, and a friction enhancing surface on at least a portion of the outside surface of the core to prevent the separator material from lateral migration relative to the outside surface of the core.