3D Battery Separator Weaving for Accurate Cell Performance Prediction
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Solution Overview
Problem
Existing digital twin technologies for rechargeable batteries focus on modeling three-dimensional electrode structures but lack the capability to verify the characteristics of the separator component, making it difficult to predict its performance and optimize battery cell design.
Innovation Solution
A method and device for forming a three-dimensional separator structure using polyethylene and polypropylene separator weaving algorithms, with error correction and simulation steps to ensure precise formation and lamination, and calculating shape parameters based on design and machine parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If digital twin technology is used to model three-dimensional electrode structures, then the cost and time of actual battery processes are reduced, but the capability to verify separator characteristics is lost
Solution Approach 1:
The battery system is segmented into distinct components (electrodes and separators), with separate modeling algorithms for each. The electrode modeling uses existing digital twin technology while the separator modeling introduces a new weaving algorithm, allowing independent verification of separator characteristics without compromising overall system efficiency.
Solution Approach 2:
The digital twin platform is enhanced with multi-functionality by integrating both electrode modeling capabilities and the new separator weaving algorithm. This universal platform can now verify characteristics of both electrodes and separators, maintaining the time and cost benefits while adding comprehensive component verification.
2Device complexity
If separator structure is not modeled in digital twin technology, then the modeling process remains simple, but performance prediction and optimization of battery cells become difficult
Solution Approach 1:
The patent applies local quality by introducing detailed separator modeling only in the specific regions where separator characteristics affect battery performance. The polyethylene and polypropylene separator weaving algorithms model pore structures, thickness variations, and material distribution locally, enabling accurate performance prediction without requiring complete re-modeling of the entire battery system.
Solution Approach 2:
The separator modeling transitions from two-dimensional representations to three-dimensional digital twin models. The weaving algorithm generates 3D pore structures, fiber arrangements, and thickness profiles that capture the spatial complexity of separators, enabling accurate performance prediction while maintaining computational efficiency through selective detailed modeling.
Data Source
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AI summary
The present disclosure relates to a method and a device for forming a three-dimensional separator structure, and a method and device for calculating shape parameters of the three-dimensional separator structure formed thereby. The method of forming the three-dimensional separator structure according to an embodiment of the present disclosure includes a separator former determining the size of a domain and voxels based on design parameters input into a processor for a separator structure, selecting a polyethylene separator weaving algorithm or a polypropylene separator weaving algorithm based on components of the separator structure and whether the separator structure is multi-layered, and forming a separator within the domain using the selected algorithm and the design parameters.