Separator Assembly With Reference Electrode and Thermal Barrier

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Solution Overview

Problem

Existing lithium-class battery cells lack effective in-stack measurement of electrode electrical characteristics and adequate thermal management, leading to potential battery failure and reduced performance in electric-drive vehicles.

Innovation Solution

Incorporating a functional separator assembly with a conductive current collector layer, a reference electrode layer, and a thermal barrier layer into the electrode stack, which allows for in-stack measurement of electrode electrical characteristics while ensuring electrical and thermal separation of neighboring working electrodes, enhancing thermal and mechanical stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a standard separator is used between electrodes, then electrical insulation is provided, but thermal management and in-stack measurement capabilities are insufficient

Engineering Contradiction:

Improvebattery failure detectionVSAvoidseparator structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into a single separator assembly: electrical insulation, thermal management, and in-stack measurement capabilities are integrated into one component structure, eliminating the need for separate systems while improving reliability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The separator assembly is designed to perform multiple functions simultaneously: it provides electrical insulation between electrodes, manages thermal conditions through barrier layers, and enables in-stack measurement of electrode characteristics through integrated sensing capabilities

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Quantity of substance

If neighboring working electrodes are placed close together, then energy density is improved, but thermal and electrical separation becomes inadequate

Engineering Contradiction:

Improveenergy densityVSAvoidthermal separation

Core Design Contradiction:

Quantity of substanceVSTemperature

Solution Approach 1:

The separator assembly incorporates a thermal barrier layer with specific thermal insulation properties positioned between neighboring working electrodes, providing localized thermal management exactly where needed to enable closer electrode placement while maintaining safety

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The thermal barrier layer acts as an intermediary component between neighboring working electrodes, mediating thermal interactions and enabling closer electrode spacing by preventing excessive heat transfer while maintaining electrical insulation

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If in-stack measurement of electrode electrical characteristics is implemented, then battery performance monitoring is improved, but device complexity increases

Engineering Contradiction:

Improveelectrode electrical characteristics measurementVSAvoidseparator assembly structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The measurement functionality is merged into the separator assembly structure itself, with sensing elements integrated directly into the separator layers, allowing in-stack measurement without adding separate monitoring systems to the battery cell

Inventive Principle:

Principle #5Merging (Combining)

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

Enables real-time monitoring of battery performance, improving cell life, driving range, and pack performance by detecting battery failure and optimizing operation, thereby enhancing thermal and mechanical stability.

Implementation Method 1

a separator layer that is fabricated from an electrically insulating material and has a porous structure that transmits therethrough the ions of the electrolyte

Methodology Applied

Scientific EffectIon transport through porous material: Porosity

Implementation Method 2

a thermal barrier layer that is fabricated from a thermally insulating material

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

a reference electrode layer that is fabricated from an active electrode material

Methodology Applied

Scientific EffectElectrochemical potential measurement:

Data Source

PatentUS12355104B2Multifunctional electrode separator assemblies with built-in reference electrodes and thermal enhancements

Publication Date: 2025.07.08 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

Presented are electrochemical devices with in-stack reference electrodes, methods for making/using such devices, and battery cells with stacked electrodes segregated by electrode separator assemblies including thermal barriers and built-in reference electrodes. An electrochemical device, such as a lithium-class secondary battery cell, includes an insulated and sealed housing with an ion-conducting electrolyte located inside the housing. A stack of working electrodes is also located inside the device housing, in electrochemical contact with the electrolyte. At least one electrode separator assembly is located inside the device housing, interposed between a neighboring pair of (anode and cathode) working electrodes. The electrode separator assembly includes a separator layer fabricated with an electrically insulating material that is sufficiently porous to transmit therethrough the ions of the electrolyte. An electrically conductive current collector (CC) layer, a thermally insulating thermal barrier (TB) layer, and an active electrode reference electrode (RE) layer are attached to the separator layer.