Battery Separator Coating With Silane Binder for Easy Recycling
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Solution Overview
Problem
The recycling of organic-inorganic composite porous separators is hindered by complex, costly, and time-consuming processes for releasing the inorganic particle layer, which can lead to physical property deterioration and environmental concerns due to organic solvent use.
Innovation Solution
A separator with an inorganic particle layer that can be easily released through sonication, utilizing a hydrolytic condensate of a silane compound as a binder, formed by a coating slurry applied to a porous substrate, with a release rate of 70% or more, and featuring improved heat resistance and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an inorganic particle layer is coated on a porous substrate to improve thermal stability, then thermal stability is improved, but recycling becomes complex and time-consuming
Solution Approach 1:
The inorganic particle layer is pre-formed on the porous substrate using a slurry composition containing inorganic particles and binder polymer. This preliminary formation allows the layer to be easily removable during recycling by simple water washing, avoiding complex recycling processes while maintaining thermal stability during battery operation
Solution Approach 2:
The binder polymer undergoes phase change at elevated temperatures, transforming from a state that firmly binds inorganic particles during battery operation to a state that easily releases particles during recycling. This parameter change enables the binder to provide strong adhesion at operating temperatures while allowing simple removal during recycling through water washing
2Ease of manufacture
If an inorganic particle layer is released using organic solvent treatment, then the inorganic particle layer can be removed, but organic solvent remains and adversely affects physical properties and causes environmental pollution
Solution Approach 1:
Water is used as an intermediary substance to replace organic solvents in the recycling process. The binder polymer's phase change properties enable it to release inorganic particles when exposed to water, achieving effective particle layer removal without the harmful effects of organic solvent residues. This intermediary approach eliminates environmental pollution concerns while maintaining effective recycling
Solution Approach 2:
The binder polymer acts as a temporary, disposable bonding agent that serves its purpose during battery operation and then easily degrades or releases particles during recycling. This disposable nature of the binder allows simple water-based recycling without requiring complex solvent removal processes, eliminating environmental pollution from organic solvent residues
3Reliability
If an inorganic particle layer is provided on the porous substrate, then thermal stability is improved, but physical properties deteriorate during recycling
Solution Approach 1:
The inorganic particle layer is pre-formed with a binder polymer that is designed to easily release particles during recycling. This preliminary formation with a removable binder allows the particle layer to maintain thermal stability during battery operation while enabling simple water washing to remove particles, preventing physical property deterioration in recycled products
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 enables a simple and efficient recycling process with enhanced thermal stability and heat resistance, as evidenced by high release rates and low heat shrinkage rates, while minimizing environmental impact.
Implementation Method 1
a release rate of the inorganic particle layer represented by the following Formula (1) is 70% or more when measured by immersing the separator in a water tank at room temperature and then subjecting the separator to sonication under conditions of a frequency of 40 kHz, an output of 1,000 W, and an application time of 60 seconds
Implementation Method 2
an inorganic particle layer formed on at least one surface of the porous substrate... utilizing a hydrolytic condensate of a silane compound as a binder
Data Source
AI summary
A separator, a method of manufacturing the separator, and an electrochemical device including the separator. The separator includes: a porous substrate; and an inorganic particle layer formed on at least one surface of the porous substrate, wherein a release rate of the inorganic particle layer is 70% or more when measured by immersing the separator in a water tank at room temperature and then subjecting the separator to sonication under conditions of a frequency of 40 kHz, an output of 1,000 W, and an application time of 60 seconds.