Integrated Battery Separator With Cooling Ducts and Electrode Support
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Solution Overview
Problem
Conventional traction battery separators in electric vehicles lack integration of mechanical and functional properties necessary for compact, lightweight, and efficient energy storage, particularly in terms of electrical isolation, mechanical stability, and cooling systems.
Innovation Solution
A functionally integrated separator with a conductive structure for electrode connection, a duct system for cooling fluid flow, and time-delayed curing material, manufactured via additive methods like 3D printing, which provides mechanical strength and porosity for ion transport, and can embed electrodes and busbars for enhanced stability and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional separators are used for spatial separation and electrical isolation, then the basic function of preventing electrical shorts is achieved, but the battery cell lacks mechanical stability, cooling capability, and compact integration
Solution Approach 1:
The patent combines multiple functions (spatial separation, electrical isolation, mechanical support, cooling fluid flow, and electrode connection) into a single integrated separator structure. The separator includes a receptacle for the galvanic cell, conductive material for electrical connection, and integrated cooling ducts, eliminating the need for separate components and achieving compact battery cell design
Solution Approach 2:
The separator is designed as a multi-functional component that simultaneously performs spatial separation of electrodes, electrical isolation, mechanical support for electrodes, fluid flow for cooling, and electrical connection through integrated conductive elements. This universal design reduces the number of separate components needed in the battery cell
2Weight of moving object
If separate components are used for mechanical support, electrical connection, and cooling, then each function can be optimized independently, but the overall battery cell becomes heavier and less compact
Solution Approach 1:
Multiple battery cell components (separator, mechanical support structure, cooling ducts, and electrical connection elements) are merged into a single integrated separator produced via additive manufacturing. This consolidation eliminates the need for separate components and assembly steps, reducing overall weight while maintaining manufacturing feasibility through digital design and additive production
Solution Approach 2:
The patent utilizes parameter changes in material properties during additive manufacturing, including time-delayed curing materials that transition from liquid to solid state, and conductive materials that can be selectively deposited. These parameter changes enable the creation of complex integrated structures with varying mechanical and electrical properties in different regions of the separator
3Productivity
If traditional manufacturing methods are used for separators, then production processes are well-established, but integration of cooling systems and electrical connections requires additional assembly steps
Solution Approach 1:
The separator integrates cooling ducts, electrical connection elements, and mechanical support structures into a single component produced via additive manufacturing. This merging eliminates multiple assembly steps and reduces the number of separate components, significantly improving productivity in battery cell manufacturing
Solution Approach 2:
The additive manufacturing process creates the integrated separator structure with all functional elements (cooling ducts, conductive paths, receptacles) already in their final positions and configurations. This preliminary formation of the complete structure eliminates the need for subsequent assembly operations, as the separator arrives at the assembly stage already fully integrated
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
Enables the construction of compact, lightweight battery cells with improved mechanical stability, reduced material requirements, and efficient cooling, while maintaining electrical isolation and ion transport capabilities, resulting in smaller, lighter batteries with enhanced performance.
Implementation Method 1
a structure composed of conductive material for electrically connecting the anode and cathode to one another
Implementation Method 2
a duct system for forming a cooling fluid flow in the or through the separator
Implementation Method 3
The separator can be provided, for example, in the form of a separator film sheet between the anode and cathode electrodes. As an alternative, a separator for the entire cell can be provided
Data Source
AI summary
A separator for spatially separating and electrically isolating electrodes in a battery cell. The separator has a receptacle for at least one galvanic cell which includes an anode and a cathode; a structure composed of conductive material for electrically connecting the anode and cathode to one another and for making contact with the at least one galvanic cell from outside; and a duct system for forming a cooling fluid flow in the separator. At least the receptacle and the duct system are integrally formed in the separator.