Variable-Thickness Cell Separator for Battery Edge Sealing
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Solution Overview
Problem
Existing cell separating elements in battery modules do not effectively protect against thermal runaway and gas penetration between battery cells, particularly in the edge regions where battery cells have rounded corners, and lack sufficient adaptability to the geometric design of prismatic cells.
Innovation Solution
A cell separating element with an elastically compressible foam layer made of polymeric material, featuring a greater thickness in the edge regions than in the central region, designed to fit the rounded edges of prismatic battery cells, and manufactured using injection molding or extrusion processes to create a 3D geometry, enhancing sealing and fire protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cell separating elements are designed as flat planar elements, then they are easy to manufacture and install, but they cannot effectively seal the widened spaces in edge regions where battery cells have rounded corners
Solution Approach 1:
The patent transitions from two-dimensional flat planar elements to three-dimensional elements with variable thickness. The edge regions protrude beyond the central region, creating a 3D geometry that adapts to the rounded corners of battery cells. This dimensional change enables the sealing surface to contact both the flat and rounded surfaces of the cells, effectively sealing the widened edge spaces while maintaining manufacturability through injection molding or extrusion processes.
2Temperature
If cell separating elements have uniform thickness, then they provide consistent thermal insulation, but they cannot adapt to the geometric design of prismatic cells with rounded edges
Solution Approach 1:
The patent applies local quality by creating regions of different thickness within the same cell separating element. The edge regions have greater thickness than the central region, allowing each region to perform its specific function: edge regions adapt to rounded corners and provide enhanced sealing, while the central region provides consistent thermal insulation. This localized differentiation resolves the contradiction between uniform thermal protection and geometric adaptability.
3Reliability
If cell separating elements are made with greater thickness in edge regions, then sealing and fire protection are improved, but manufacturing complexity increases
Solution Approach 1:
The patent changes the geometric parameter of thickness across different regions of the cell separating element. By systematically varying the thickness parameter (greater at edges, uniform in center), the patent achieves improved fire protection and sealing without excessive complexity. The variable thickness design is implemented through standard injection molding or extrusion processes, making the geometric complexity manageable and manufacturable.
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 provides improved sealing and fire protection by adapting to the geometric shape of prismatic cells, preventing gas penetration and enhancing thermal insulation, thereby protecting neighboring cells from thermal runaway.
Implementation Method 1
at least one elastically compressible foam layer comprising a polymeric material
Implementation Method 2
provide thermal decoupling of the adjacent battery cells through a correspondingly low thermal conductivity of the cell separating elements
Data Source
AI summary
A cell separating element for arrangement between two battery cells of a battery module including at least one elastically compressible foam layer which have a polymeric material. The cell separating element has two outer sides which are opposite one another with respect to a first direction and the spacing of which in the first direction defines a thickness of the cell separating element, and the cell separating element has a first edge region which delimits the cell separating element with respect to a second direction. The thickness of the cell separating element is greater in the first edge region than in a central region of the cell separating element.