Battery Separator Plate Indentions Manage Cell Swelling
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Solution Overview
Problem
Traditional battery modules face issues with electrical shorts, thermal expansion, and inaccurate positioning of electrochemical cells, which can negatively affect the cells and the housing, leading to inefficiencies and reduced lifespan.
Innovation Solution
The use of separator plates with specific design features such as tabs, indentions, and channels to separate and align electrochemical cells, preventing electrical shorts and allowing for thermal expansion while facilitating cooling and improved positioning within the battery module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electrochemical cells are positioned closely together to maximize battery module density, then productivity and space utilization are improved, but the risk of electrical shorts and thermal expansion damage increases
Solution Approach 1:
A separator plate is introduced as an intermediary component between adjacent electrochemical cells. The separator plate includes a body portion positioned between the cells and tabs that extend to contact terminals, providing both physical separation to prevent electrical shorts and structural support for terminal alignment.
Solution Approach 2:
The separator plate is segmented into distinct functional portions: a body portion for physical separation and tab extensions for electrical terminal management. This segmentation allows each portion to perform its specific function optimally while working together as an integrated component.
2Manufacturing precision
If electrochemical cells are constrained rigidly to maintain precise positioning, then manufacturing precision is improved, but the ability to accommodate thermal expansion deteriorates
Solution Approach 1:
The separator plate body portion is designed with specific dimensional parameters including thickness and tab lengths that are optimized to provide both positioning precision and expansion space. The tabs extend beyond the body portion by controlled amounts to maintain terminal alignment while accommodating cell dimensional changes during operation.
Solution Approach 2:
The separator plate design allows for dynamic adjustment during cell operation. The tabs maintain electrical terminal alignment while the body portion accommodates dimensional changes of the cells during charging, discharging, and thermal cycles, transitioning from a static to a dynamic adaptation approach.
3Reliability
If separator plates are designed with extensive tabs to block electrical shorts, then reliability is improved, but device complexity increases
Solution Approach 1:
The separator plate is designed as a multi-functional component that simultaneously provides physical separation between cells, structural support for terminal alignment, and electrical isolation through its tab extensions. This universal design consolidates multiple functions into a single component, reducing overall device complexity while maintaining reliability.
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 effectively prevents electrical shorts, manages thermal expansion, and enhances the lifespan of electrochemical cells by providing a controlled environment for swelling and cooling, thereby improving the overall performance and reliability of the battery module.
Implementation Method 1
The separator plate is disposed between the first electrochemical cell and the second electrochemical cell... The separator plate comprises a large tab extending between the first and third terminals... The large tab comprises a first upper edge disposed no higher than top surfaces of the first terminal and the third terminal
Implementation Method 2
The first side is disposed adjacent a first face of the first electrochemical cell and includes a first indention. The first indention defines a first space between the first face of the first electrochemical cell and the first side of the body of the separator plate. The first space is configured to enable swelling of the first electrochemical cell into the first space.
Data Source
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AI summary
The present disclosure includes a battery module having a first electrochemical cell and a second electrochemical cell positioned adjacent to the first electrochemical cell. The battery module also includes a separator plate disposed between the first electrochemical cell and the second electrochemical cell. The separator plate includes a body comprising a first side and a second side opposite the first side. The first side is disposed adjacent a first face of the first electrochemical cell and includes a first indention. The first indention defines a first space between the first face of the first electrochemical cell and the first side of the separator plate. The first space is configured to enable swelling of the first electrochemical cell into the first space.