Elastically Deformable Battery Cell Separator Design
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Solution Overview
Problem
Conventional power supply devices using stacked battery cells face challenges in efficiently insulating surfaces to prevent short circuits and corrosion, leading to complex assembly processes and increased production costs due to the need for shrink tubes and alternating stacking of battery cells and separators.
Innovation Solution
A power supply device featuring elastically deformable separators with box-shaped and corner covering sections that cover the battery cell surfaces, eliminating the need for shrink tubes and simplifying assembly by allowing for easier stacking and insulation, while also incorporating air passages for cooling and enhanced creepage distances to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shrink tubes are used to cover the surface of external cases for insulation, then insulation effectiveness is improved, but workability deteriorates and production cost increases
Solution Approach 1:
The separator is divided into multiple functional sections: a main body portion for general insulation, a bottom covering portion extending to cover the bottom surface, and side covering portions for side surfaces. This segmentation allows each part to perform its specific insulation function without requiring separate shrink tubes, improving workability while maintaining insulation effectiveness.
Solution Approach 2:
The separator serves multiple functions simultaneously: it provides insulation between adjacent battery cells, covers the bottom and side surfaces of external cases to prevent dew condensation and corrosion, and maintains structural support for the battery stack. This multi-functionality eliminates the need for separate insulating components, reducing production cost and improving workability.
2Reliability
If battery cells and separators are stacked in an alternating fashion, then insulation between battery cells is improved, but assembly complexity increases and productivity decreases
Solution Approach 1:
The separator is designed to cover not only the main surface but also the bottom and side surfaces of the battery cell in an integrated structure. This merging of insulation functions into a single component allows battery cells to be stacked directly without requiring alternating placement of separate separators, simplifying assembly and improving productivity while maintaining insulation effectiveness.
3Reliability
If the bottom surfaces of external cases are insulated to prevent short circuits from condensed water, then reliability is improved, but device complexity increases
Solution Approach 1:
The separator includes a specifically designed bottom covering portion that extends from the main body to cover the bottom surface of the external case. This segmentation ensures that condensed water cannot cause short circuits between adjacent battery cells while maintaining a relatively simple overall structure that does not require additional insulating components.
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 effectively prevents short circuits and corrosion, simplifies the assembly process, reduces production costs, and improves productivity by ensuring reliable insulation and efficient cooling of battery cells.
Implementation Method 1
The separator is formed from an elastically deformable insulating material
Implementation Method 2
a first air blowing channel formed on the first surface of the main plate section for forming an air passage between the battery cell, which is to be stacked on a side of the first surface of the main plate section, and the main plate section
Data Source
AI summary
A power supply device is provided with: a plurality of battery cells, each of which has a prismatic external form; a separator connected to each battery cell to cover at least a portion of the surface of the battery cell; and a fastening member that fastens a battery stack obtained by stacking the battery cells covered by the separator in a state where main surfaces face each other. The separator is formed from an insulating material which is elastically deformable, and provided with the main plate section covering the main surface of the battery cell disposed to face said section, a box-shaped covering section provided on a bottom part of the main plate section on a side of a first surface, and a corner covering section provided on a top part of the main plate section on the side of the first surface.