Fluid-Filled Cell Separator Mount for Swelling and Thermal Isolation
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Solution Overview
Problem
Existing cell separating elements in high-voltage batteries require multiple components to achieve functions like swelling compensation and thermal insulation, leading to increased material usage, installation space, weight, and manufacturing complexity, while also complicating disassembly.
Innovation Solution
A cell separating element with a first and second wall forming a cavity filled with fluid, featuring an attachment flap for secure attachment to battery cells, providing thermal insulation, swelling compensation, and optional cooling without additional components, using a pad that can be compressed to counteract cell swelling and insulate against thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components are used to achieve swelling compensation and thermal insulation functions, then the functional requirements are met, but the material usage, installation space, weight, and manufacturing complexity increase
Solution Approach 1:
The patent merges multiple previously separate components (swelling compensation element, thermal insulation element, and attachment element) into a single integrated cell separating element. This is achieved by forming a monolithic structure that simultaneously provides swelling compensation through its compressible material properties, thermal insulation through its material composition, and attachment functionality through integrated attachment flaps, thereby reducing the total number of components while maintaining all required functions
Solution Approach 2:
The cell separating element is designed as a universal component that performs multiple functions simultaneously: it compensates for cell swelling through its compressible elastomeric material, provides thermal insulation between adjacent cells through its material properties and structure, and enables attachment to battery cell housings through integrated attachment flaps. This multi-functional design eliminates the need for separate specialized components for each function
2Stability of the object's composition
If cell separating elements are adhered to battery cells to maintain position, then the positioning is secured, but the disassembly process is impeded
Solution Approach 1:
The attachment system transitions from a static adhesive bond to a dynamic mechanical attachment using flaps that can be engaged and disengaged. The attachment flaps are designed to provide stable positioning during operation while allowing for controlled release during disassembly, enabling the system to adapt between its two operational states (assembly/maintenance and disassembly)
3Reliability
If the pad is filled with fluid for swelling compensation, then the swelling control is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent changes the physical state parameter of the fluid filling from a variable that requires complex sealing and filling processes to a simplified configuration where the fluid is enclosed in a pre-formed cavity within the elastomeric material itself. This parameter change in the manufacturing approach (from post-forming filling to integrated cavity design) maintains the swelling compensation effectiveness while dramatically simplifying the manufacturing process
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 integrates multiple functions into a single, lightweight component that simplifies assembly, enhances mechanical stability, and ensures effective thermal insulation and swelling compensation, while allowing for efficient manufacturing and disassembly.
Implementation Method 1
A cell separating element for arrangement at a prismatic battery cell (16) includes a first wall (20) and a second wall (22) opposing the first wall (20), between which a cavity (24) filled or fillable with a fluid (15) is formed, whereby a pad (12) filled or fillable with the fluid (15) is provided
Implementation Method 2
Therein, it is advantageous if cell separating elements are installed between the cells, which provide a thermal insulation for example in the manner that a runaway cell is thermally insulated as far as the adjacent cells do not also catch fire or get in thermal runaway
Data Source
AI summary
A cell separating element is for arrangement at a prismatic battery cell. The cell separating element includes a first wall and a second wall opposing the first wall, between which a cavity filled or fillable with a fluid is formed to provide a pad filled or fillable with the fluid. The cell separating element divides into a pad area and a cell separating element peripheral area surrounding the pad area in closed manner in a circumferential direction, in which the first wall and the second wall are connected to each other. A first part of a first peripheral area of the first wall is formed as an attachment flap to attach the cell separating element to the battery cell and is arranged angled at an angle (a) to a second part of the first peripheral area adjoining to the pad area and situated in a pad plane of the pad.