3D Separator Structure for Compact Energy Cell Support and Sealing
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Solution Overview
Problem
Existing energy devices face challenges in reducing size and weight while maintaining mechanical strength, preventing short circuiting, and ensuring efficient power delivery, particularly in applications like electric and hybrid vehicles.
Innovation Solution
A three-dimensional separator for energy devices, comprising a perimeter wall, step portion, and planar membrane with perforations, provides mechanical support, seals electrolyte, and prevents short circuiting, while being made of electrically insulating yet ionically conducting material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multiple thin planar unit cells are used to reduce volume, then the volume of the energy device is reduced, but the mechanical support and prevention of short circuiting become more difficult
Solution Approach 1:
The separator transitions from a traditional two-dimensional planar structure to a three-dimensional structure with perimeter walls extending vertically and step portions creating multiple levels. This dimensional enhancement allows the separator to provide mechanical support and electrical insulation in the vertical dimension while maintaining the compact volume of thin planar unit cells.
Solution Approach 2:
The separator is constructed from composite materials that combine electrical insulation properties with mechanical strength. The three-dimensional structure incorporates different material zones (perimeter walls, step portions, planar membrane) that work together to provide both structural support and prevent short circuiting between electrodes.
2Strength
If the separator structure is made more complex to provide mechanical support and sealing, then mechanical strength and sealing are improved, but the ease of manufacture decreases
Solution Approach 1:
Multiple functions (mechanical support, electrical insulation, sealing, and structural organization) are merged into a single integrated three-dimensional separator component. The perimeter walls, step portions, and planar membrane are formed as one unitary structure, eliminating the need for separate components and simplifying the manufacturing process while maintaining enhanced mechanical strength and sealing capabilities.
3Volume of moving object
If the planar membrane thickness is reduced to minimize volume, then the volume is reduced, but the mechanical support capability is weakened
Solution Approach 1:
The separator design compensates for reduced planar membrane thickness by adding vertical dimension through perimeter walls and step portions. The three-dimensional structure provides mechanical support primarily through the vertical walls rather than relying on the thickness of the planar membrane, allowing the membrane to remain thin for volume reduction while maintaining overall structural strength.
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 three-dimensional separator enhances mechanical support, seals electrolyte, and prevents short circuiting, enabling efficient power delivery and ease of production in energy devices.
Implementation Method 1
a three dimensional separator for use in a unit cell of an energy device... made of electrically insulating yet ionically conducting material... The planar membrane includes perforations
Implementation Method 2
A perimeter wall and a step portion extending from the perimeter wall along an inner surface of the perimeter wall... configured to form a seal around edges of layers forming the unit cell
Implementation Method 3
provides mechanical support, sealing of liquid or cell components... a three dimensional separator... that provides mechanical support
Data Source
AI summary
A separator for use in a unit cell of an energy device includes a perimeter wall and a step portion extending from the perimeter wall along an inner surface of the perimeter wall. A midpoint of a height of the perimeter wall is aligned with a midpoint of a height of the step portion. A planar membrane extends across an area defined by an innermost surface of the step portion. The planar membrane is aligned with the midpoint of the height of the step portion. The planar membrane includes perforations.