Secondary Battery Separator Manufacturing Using Safe Dissolution
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Solution Overview
Problem
The manufacturing methods for secondary battery separators with three-dimensionally ordered pores require the use of hydrofluoric acid, which is hazardous and increases costs.
Innovation Solution
A method involving the preparation of a slurry with uniformly dispersed spherical microparticles, heat-treating to form a microparticles-resin film, and then using organic acids, water, or alkaline solutions other than hydrofluoric acid to create pores with a three-dimensionally ordered structure, eliminating the need for hydrofluoric acid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hydrofluoric acid is used to dissolve and remove silica particles, then pores with three-dimensionally ordered structure are formed, but handling difficulty and manufacturing cost increase
Solution Approach 1:
The patent replaces expensive and hazardous hydrofluoric acid with cheaper, safer alternatives such as organic acids (acetic acid, formic acid), alkaline solutions (sodium hydroxide, potassium hydroxide), or water. These substitutes achieve the same pore-forming function without the handling difficulties and high costs associated with hydrofluoric acid, while maintaining the three-dimensionally ordered pore structure
Solution Approach 2:
The patent changes the chemical parameters of the dissolution medium from hydrofluoric acid to safer alternatives with different pH characteristics (organic acids, alkaline solutions, or water). This parameter change allows the silica particles to be removed effectively while avoiding the hazards and costs of hydrofluoric acid, achieving the same structural outcome through different chemical pathways
2Manufacturing precision
If hydrofluoric acid is used to dissolve and remove silica particles, then pores with three-dimensionally ordered structure are formed, but handling safety deteriorates
Solution Approach 1:
The patent substitutes hazardous hydrofluoric acid with safer, readily available substances such as organic acids, alkaline solutions, or water. These alternatives eliminate the severe handling safety issues associated with hydrofluoric acid while maintaining the ability to form three-dimensionally ordered pores through dissolution of silica particles
Solution Approach 2:
The patent converts the previously harmful hydrofluoric acid step into a beneficial process by using safe alternatives. The dissolution step that was previously hazardous is transformed into a safe, controllable process using common chemicals, thereby eliminating the harmful factors while preserving the pore-forming function
3Manufacturing precision
If monodisperse spherical silica particles are used as templates, then three-dimensionally ordered pores are formed, but the process requires hazardous hydrofluoric acid
Solution Approach 1:
The patent replaces the hazardous chemical agent (hydrofluoric acid) with safe alternatives (organic acids, alkaline solutions, or water) that can equally dissolve silica particles. This substitution maintains the pore uniformity achieved through monodisperse spherical templates while eliminating the chemical hazard associated with the original dissolution method
Solution Approach 2:
The patent changes the dissolution parameters from hydrofluoric acid to safer chemicals with different solubility characteristics. By adjusting pH, temperature, and concentration parameters of the alternative dissolution media, the process achieves the same pore uniformity without the harmful effects of hydrofluoric acid
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 method safely and cost-effectively manufactures secondary battery separators with three-dimensionally ordered pores, enhancing the manufacturing process by avoiding the handling risks and costs associated with hydrofluoric acid.
Implementation Method 1
uniformly dispersing spherical microparticles having narrow particle size distribution in a dispersion medium to prepare a microparticles-dispersed slurry
Implementation Method 2
drying the microparticles-dispersed slurry to obtain a spherical microparticles-dispersed film
Implementation Method 3
heat-treating the spherical microparticles-dispersed film to form a microparticles-resin film in which the microparticles are regularly arrayed in three-dimensions
Implementation Method 4
contacting the microparticles-resin film with an organic acid, water, an alkaline solution or an inorganic acid other than hydrofluoric acid to dissolve and remove the microparticles
Implementation Method 5
heating the microparticles-resin film to remove the microparticles, to form pores which are in mutual communication via through-holes and regularly arrayed in three-dimensions
Data Source
AI summary
A method for manufacturing, a secondary battery separator including a porous resin film in which pores have three-dimensionally ordered structure and are in mutual communication via through-holes. The method includes: uniformly dispersing spherical microparticles having narrow particle size distribution in a dispersion medium to prepare a microparticles-dispersed slurry; drying slurry to obtain a spherical microparticles-dispersed film; heat-treating the film to form a microparticles-resin film in which the microparticles are regularly arrayed in three-dimensions in a resin matrix; and contacting the microparticles-resin film with an organic acid, water, an alkaline solution or an inorganic acid other than hydrofluoric acid to dissolve and remove the microparticles, or heating the microparticles-resin film to remove the microparticles, to form pores which are in mutual communication and regularly arrayed in the resin matrix. The medium has a resin precursor for the resin matrix and surfaces of the microparticles are inactive against the medium.