Wet-State Separator Composition for SLA Battery Gas Permeation
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Solution Overview
Problem
Conventional separators for sealed lead-acid batteries suffer from uneven fiber distribution and orientation, leading to non-uniform gas absorption reactions, electrolyte concentration variations, and increased energy costs due to excessive gas absorption reactions, which can cause battery thermal runaway.
Innovation Solution
A separator formed from micro-glass fibers with controlled gas permeation rates and permeability, blended with long glass fibers, organic fibers, and inorganic powder, to ensure uniform fiber distribution and orientation, thereby regulating electrolyte concentration and preventing abnormal heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separator with high gas permeability is used to promote oxygen absorption reaction, then battery capacity is improved, but electrolyte concentration becomes too low and battery performance deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the gas permeation rate and gas permeability of the separator to specific ranges (gas permeation rate: 1-15 mm/min, gas permeability: 20-70%). This optimization balances oxygen absorption reaction promotion with electrolyte concentration maintenance, resolving the contradiction between battery capacity and electrolyte concentration.
2Ease of manufacture
If conventional wet-formed sheet separators are used, then production is simplified, but fiber distribution becomes uneven and surface smoothness is poor
Solution Approach 1:
The patent uses composite materials by combining micro-glass fibers (50-90 wt%) with long glass fibers (5-30 wt%). This composite structure improves fiber distribution uniformity and surface smoothness while maintaining production simplicity, as the combination leverages the advantages of both fiber types without requiring complex manufacturing processes.
3Productivity
If papermaking rate is increased to improve productivity, then production cost is reduced, but fiber orientation becomes non-uniform and directionality increases
Solution Approach 1:
The patent applies parameter changes by optimizing the papermaking rate to a specific range (3-15 m/min). This controlled parameter change ensures uniform fiber orientation and minimizes directionality while maintaining high productivity, resolving the contradiction between production efficiency and fiber orientation uniformity.
4Reliability
If excessive gas absorption reaction occurs during chemical conversion, then oxygen gas is absorbed, but electrolyte concentration decreases and additional energy is required for adjustment
Solution Approach 1:
The patent applies parameter changes by precisely controlling the separator's gas permeation rate (1-15 mm/min) and gas permeability (20-70%). This optimization prevents excessive gas absorption reaction during chemical conversion, maintaining electrolyte concentration within the desired range and eliminating the need for additional energy-consuming adjustments.
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 separator effectively controls gas permeation, allowing precise adjustment of electrolyte concentration and preventing battery overheating, enhancing battery performance and safety.
Implementation Method 1
a gas permeation rate of 15 mm/min or less and/or a gas permeability of 70% or less in a wet state
Implementation Method 2
a separator that is optimal for adjusting the specific gravity of the electrolyte during chemical conversion
Implementation Method 3
The oxygen gas generated here is absorbed by the negative electrode and water is generated
Data Source
Figure 1
AI summary
[Problem] The invention has been made by focusing on the fact that a conventional separator with a specified fiber distribution or fiber orientation was unable to sufficiently control the gas absorption reaction, which is one of the basic functions of a sealed lead-acid battery, and, in order to control the gas permeation ability itself of the separator, the invention makes it possible to provide an optimum separator which can reduce the amount of adjustment of the electrolyte concentration (specific gravity) after chemical conversion in a container of a sealed lead-acid battery, and can prevent abnormal heat generation of the battery in an actual battery use environment. [Solution] Preparation is performed so that the gas permeation rate in a wet state of a separator is 15 mm/min or less, and/or the gas permeability in a wet state of the separator is 70% or less.