Battery Separator Temperature Probe for Precise Cell Stack Monitoring
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Solution Overview
Problem
Existing battery pack temperature monitoring systems lack efficiency and precision in monitoring the temperature of stacked battery cells, which can impact battery efficiency and detect potential faults.
Innovation Solution
An integrated temperature probe structure is disposed on the permeable separator between the anode and cathode layers of a battery cell, comprising two materials with overlapping regions, where the voltage differential between sensor terminals corresponds to the average temperature of the overlap region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional temperature monitoring systems are used for battery cells, then temperature measurement is possible, but measurement precision and efficiency are insufficient
Solution Approach 1:
The patent combines the temperature sensing function with the existing battery separator structure. The separator serves dual purposes: electrical insulation between electrodes and temperature monitoring through integrated thermocouple materials. This merging eliminates the need for separate temperature sensors and reduces system complexity while improving measurement precision through direct contact with the battery interior environment.
Solution Approach 2:
The patent introduces thermocouple materials as intermediary substances coated on the separator. These materials generate voltage signals proportional to temperature differences, acting as mediators that convert thermal energy into measurable electrical signals. This intermediary mechanism enables precise temperature measurement without requiring complex sensor assemblies.
2Measurement precision
If multiple temperature sensors are deployed in each cell, then measurement coverage is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The temperature monitoring function is merged into the separator manufacturing process itself. The thermocouple materials are coated or laminated onto the separator during production, allowing both components to be manufactured together in a single integrated process. This eliminates the need for separate sensor installation steps and simplifies battery assembly while maintaining high measurement accuracy.
Solution Approach 2:
The separator is designed to serve multiple functions simultaneously: electrical insulation, thermal management, and temperature monitoring. By making the separator universal and multi-functional, the patent reduces the total number of components needed and simplifies the manufacturing process while achieving comprehensive temperature monitoring coverage.
3Reliability
If temperature monitoring is added to battery cells, then fault detection capability is improved, but device complexity increases
Solution Approach 1:
The patent uses thermocouple materials as intermediary elements that passively generate temperature-related voltage signals without requiring active power consumption or complex electronics within the battery cell. The voltage signals are naturally produced by the thermocouple effect and can be read by external monitoring systems, thereby improving fault detection capability while minimizing additions to cell structure complexity.
Solution Approach 2:
The temperature monitoring system is designed to be self-generating and self-regulating. The thermocouple materials automatically produce voltage signals in response to temperature changes without requiring external power sources, control circuits, or active components within the battery cell. This self-service approach enhances reliability through passive operation while keeping the cell structure simple.
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
This solution enables accurate and efficient temperature monitoring within the battery cell stack, allowing for targeted measurements and early detection of temperature-related faults, thereby improving battery performance and reliability.
Implementation Method 1
a voltage differential between the first sensor output terminal and the second sensor output terminal corresponds to an average temperature of the overlap region
Data Source
AI summary
A battery includes multiple stacked cells. Each cell includes an anode layer and a cathode layer separated by a permeable separator. At least one temperature probe structure is disposed on the permeable separator between the anode layer and the cathode layer of a first cell of the stacked cells. The temperature probe structure includes at least a first material partially coating the permeable separator and a second material partially coating the permeable separator. The first material overlaps with the second material at an overlap region. A first sensor output terminal is connected to the first material and a second sensor terminal is connected to the second material. A voltage differential between the first sensor output terminal and the second sensor output terminal corresponds to an average temperature of the overlap region.