Battery Module Separator Structure for Heat Insulation and Cell Deformation
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Solution Overview
Problem
Existing battery modules lack effective insulation and cushioning mechanisms that maintain functionality during battery cell deformation and high temperature conditions, particularly when the cushioning portion ceases to exist.
Innovation Solution
A battery module design featuring a separator with a main body portion as a heat-insulating material and embedded portions made of an elastic material, where the embedded portions are more elastic than the main body, and are designed to maintain separation and insulation even under high temperatures and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a cushioning portion made of elastic material is provided to improve followability during battery cell deformation, then the heat insulating material can accommodate cell expansion, but the cushioning portion ceases to exist when the battery cell temperature becomes high, compromising safety
Solution Approach 1:
The heat insulating material is constructed as a composite structure combining a heat insulating portion (made of heat-resistant material like ceramic foam or aerogel) and a cushioning portion (made of elastic material like foam rubber or silicone rubber). This composite structure allows the cushioning portion to provide deformation accommodation at normal temperatures while the heat insulating portion maintains thermal isolation functionality even when the cushioning portion degrades at high temperatures.
Solution Approach 2:
Different portions of the heat insulating material are assigned different material properties: the heat insulating portion uses materials with high heat resistance and low thermal conductivity, while the cushioning portion uses materials with high elasticity and compressibility. This local differentiation allows each portion to perform its specific function optimally - the cushioning portion handles deformation at normal temperatures while the heat insulating portion ensures thermal safety at high temperatures.
2Ease of operation
If the embedded portion is made highly elastic to improve cushioning performance, then followability during cell expansion is enhanced, but the structural integrity and heat insulating performance may be compromised
Solution Approach 1:
The embedded portion is designed with spatially varying properties: it has a highly elastic outer layer or surface that contacts the battery cell to provide cushioning and followability, while the inner core or adjacent regions use stiffer, heat-resistant materials to maintain structural integrity and heat insulating performance. This local differentiation allows the embedded portion to simultaneously provide both cushioning compliance and structural strength.
Solution Approach 2:
The embedded portion is constructed as a composite structure combining elastic materials (for cushioning) with heat-resistant, structurally strong materials (for integrity and thermal isolation). This composite construction allows the embedded portion to exhibit both high elasticity for cushioning performance and sufficient strength to maintain structural integrity and heat insulating functionality under various operating conditions.
3Object-affected harmful factors
If the through hole diameter is reduced to improve heat insulation, then thermal transfer is minimized, but the embedded portion cannot adequately accommodate battery cell deformation
Solution Approach 1:
The embedded portion is constructed as a composite structure combining elastic materials (for cushioning) with heat-resistant, structurally strong materials (for integrity and thermal isolation). This composite construction allows the embedded portion to exhibit both high elasticity for cushioning performance and sufficient strength to maintain structural integrity and heat insulating functionality under various operating conditions.
Solution Approach 2:
Different portions of the heat insulating material are assigned different material properties: the heat insulating portion uses materials with high heat resistance and low thermal conductivity, while the cushioning portion uses materials with high elasticity and compressibility. This local differentiation allows each portion to perform its specific function optimally - the cushioning portion handles deformation at normal temperatures while the heat insulating portion ensures thermal safety at high temperatures.
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 design ensures effective heat insulation and cushioning, preventing thermal transfer between battery cells and maintaining module integrity during expansion and high temperatures, thereby enhancing safety and energy density.
Implementation Method 1
the main body portion is a heat insulating material having heat insulating performance higher than heat insulating performance of the embedded portion
Implementation Method 2
the embedded portion is an elastic material having elastic performance higher than elastic performance of the main body portion
Data Source
AI summary
This separator includes a main body portion and an embedded portion embedded in each of a plurality of through holes provided in the main body portion, the main body portion is a heat insulating material having heat insulating performance higher than that of the embedded portion, the embedded portion is an elastic material having elastic performance higher than that of the main body portion, and a shortest distance between one portion of an inner wall surface of an inner diameter of the through hole and another portion of the inner wall surface of the inner diameter of the through hole is 60 mm or less, the other portion of the inner wall surface being located in a direction perpendicular to the one portion of the inner wall surface.