Waste Battery Separator Composite Pellets From Ceramic-Coated Scrap
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Solution Overview
Problem
The existing methods for improving lithium secondary battery separators, particularly those coated with ceramic or aramid, face challenges in high-temperature thermal stability and physical strength, leading to a high occurrence of defective products and environmental issues due to the disposal of waste materials.
Innovation Solution
A method is developed to regenerate waste secondary battery separators coated with ceramic particles or aramid by crushing and compression-crushing them, mixing with polyolefin-based resins and additives, and processing into pellet form, which enhances processability and reduces waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic or aramid coating is applied to improve thermal stability and physical strength, then separator performance is improved, but manufacturing complexity increases and defective product rate increases
Solution Approach 1:
The patent combines the base polyolefin separator and ceramic/aramid coating into an integrated composite structure. The coating layer is applied directly onto the porous substrate during manufacturing, merging the structural support function of the base separator with the thermal stability function of the coating into a single unified component, thereby reducing overall system complexity while maintaining improved reliability
Solution Approach 2:
The patent creates a composite material structure by combining polyolefin-based porous substrate with ceramic particles or aramid coating layers. This composite approach allows the separator to simultaneously exhibit the mechanical properties of polyolefin and the thermal stability of ceramic/aramid materials, achieving enhanced reliability without requiring separate components or complex assembly processes
2Strength
If ceramic or aramid coating is applied to improve physical strength, then separator strength is improved, but occurrence of defective products increases
Solution Approach 1:
The patent optimizes coating parameters including particle size distribution, coating thickness, and binder composition to achieve uniform coating quality. By carefully controlling these parameters, the manufacturing process produces consistent physical strength across all separators while minimizing defects. The coating is applied at controlled temperatures and pressures to ensure uniform distribution of ceramic or aramid materials
Solution Approach 2:
The patent ensures that the ceramic or aramid coating is uniformly distributed across the entire separator surface, including edge regions. The coating process is designed to maintain consistent quality from center to edge, preventing the quality uniformity issues that typically plague coated products. This localized quality control ensures that every region of the separator meets the required strength specifications
3Temperature
If ultra-high molecular weight polyethylene is used with high ceramic or aramid content, then heat resistance is improved, but processability deteriorates
Solution Approach 1:
The patent introduces a polymer binder as an intermediary substance that facilitates the bonding between ultra-high molecular weight polyethylene and ceramic or aramid particles. The binder acts as a mediator that enables processability by reducing friction and improving flow characteristics during extrusion, while still allowing the high ceramic/aramid content to provide the desired heat resistance. This intermediary material makes the manufacturing process feasible without sacrificing thermal performance
Solution Approach 2:
The patent modifies processing parameters including extrusion temperature, screw speed, and die design to accommodate the high viscosity of ultra-high molecular weight polyethylene mixed with ceramic or aramid particles. By optimizing these parameters, the patent achieves both high heat resistance from the ceramic/aramid content and adequate processability for manufacturing. The processing conditions are specifically tuned to handle the challenging rheology of this composite material
4Reliability
If complex coating process is used to improve separator properties, then thermal stability is improved, but waste generation increases
Solution Approach 1:
The patent converts the typically discarded waste separator material into a valuable resource by using it as the base substrate for the composite coating process. Instead of disposing of separators that fail to meet specifications or are damaged during coating, the patent reprocesses these materials into lower-grade composite separators suitable for applications with less stringent requirements. This approach transforms waste into beneficial products, reducing landfill disposal while maintaining high thermal stability in the final composite material
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 approach creates a novel composite resin pellet with excellent economic feasibility and physical properties, suitable for various applications, reducing costs and environmental impact by utilizing waste materials effectively.
Implementation Method 1
a pretreatment step of crushing and compression-crushing the secondary battery waste separator coated with ceramic particle or aramid on one side or both sides
Implementation Method 2
compression-crushing the secondary battery waste separator coated with ceramic particle or aramid on one side or both sides
Implementation Method 3
a step of mixing the same with a polyolefin-based resin, a modifier and an additive and melting, kneading and extruding the mixture
Implementation Method 4
a step of processing the extrude into a pellet form
Data Source
AI summary
The present invention relates to a method for preparing a composite resin composition by regenerating secondary battery waste separators of which one surface or both surfaces are coated with ceramic particles or aramids, and, more specifically, to a method for preparing a composite resin composition through: i) a pretreatment step of crushing secondary battery waste separators coated with ceramic particles and compression-crushing same into a smaller volume; ii) a step of mixing the pretreated waste separator material with a polyolefin-based material having excellent fluidity, other modifiers and additives, and melting, uniformly kneading and extruding same; and iii) a step of processing same into a pellet form. The present invention relates to an economical, efficient and eco-friendly process capable of preparing a variously usable novel composite resin composition from separator scraps coated with ceramic particles or aramids, which are generated during the manufacture of secondary batteries, and separators, which are inferior goods requiring disposal.