Serrated Battery Separators with Surfactant Coatings
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Solution Overview
Problem
Industrial batteries, such as inverter batteries, face challenges with reduced re-chargeability and increased water loss due to deep discharge cycles, leading to compromised battery life and frequent watering needs.
Innovation Solution
The development of improved battery separators with a serrated profile and optimized surfactant coatings, which enhance electrolyte movement and equalization, reducing water loss and improving charge acceptance and re-chargeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional battery separators are used, then the basic separation function is maintained, but water loss increases and charge acceptance decreases during deep discharge cycles
Solution Approach 1:
The patent applies parameter changes by modifying the separator's physical structure (serrated profile with increased surface area) and chemical composition (surfactant coating with specific HLB values). These parameter modifications enable the separator to reduce water loss while improving charge acceptance during deep discharge cycles, resolving the contradiction between substance loss and reliability.
Solution Approach 2:
The patent uses composite materials by combining the base separator material with a surfactant coating layer. This composite structure integrates the separation function with water loss reduction and charge acceptance enhancement, simultaneously addressing multiple performance requirements that conventional single-material separators cannot satisfy.
2Use of energy by moving object
If deep discharge cycles are implemented, then energy storage capacity is utilized, but battery life is compromised and water loss increases
Solution Approach 1:
The patent applies beforehand cushioning by pre-coating the separator with surfactant before battery operation. This preventive measure creates a protective layer that reduces water loss and mitigates degradation effects during deep discharge cycles, thereby extending battery life while maintaining full energy storage capacity utilization.
3Productivity
If separator surface area is increased to improve electrolyte movement, then charge acceptance improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by creating a serrated profile with multiple ridges and valleys on the separator surface. This segmented structure increases the effective surface area for electrolyte interaction, improving charge acceptance while maintaining a manufacturable geometric pattern that can be produced through standardized molding processes.
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 improved battery separators result in extended battery life, reduced water loss, and increased charge acceptance, addressing the limitations of existing separators by combining a serrated profile with a high add-on level of surfactants for enhanced performance.
Implementation Method 1
A battery separator may have two primary functions. First, a battery separator should keep the positive electrode physically apart from the negative electrode in order to prevent any electronic current passing between the two electrodes. Second, a battery separator should permit an ionic current between the positive and negative electrodes with the least possible resistance.
Implementation Method 2
The instant disclosure is directed to one or more improved battery separators having various improvements that may result in decreased water loss for a battery in which such a separator is incorporated, enhanced charge acceptance
Data Source
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Figure 3(a)~3(d)
AI summary
New, improved or optimized battery separators, components, batteries, industrial batteries, inverter batteries, batteries for heavy or light industrial applications, forklift batteries, float charged batteries, inverters, accumulators, systems, methods, profiles, additives, compositions, composites, mixes, coatings, and/or related methods of water retention, water loss prevention, improved charge acceptance, production, use, and/or combinations thereof are provided or disclosed. More particularly, the present invention is directed to one or more improved battery separators having various improvements that may result in decreased water loss for a battery in which such a separator is incorporated, enhanced charge acceptance, or combinations thereof. Additionally, the present invention relates to one or more improved battery separators having various improvements with regard to shape, and/or physical profile, and/or chemical(s), additives, mixes, coatings, and/or the like used to make such battery separators (such as oil(s), and/or chemical additive(s) or agents used to coat, finish or improve such battery separators (such as surfactant(s))). The improved battery separators of the instant invention are particularly useful in or with industrial batteries, such as inverter batteries, batteries for heavy or light duty industrial applications, and so forth.