Battery Heater Layer and CCP Venting for Cold-Start Cell Warming
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Solution Overview
Problem
Lithium-ion batteries experience significant performance degradation at low temperatures due to poor electrolyte conductivity, lithium intercalation kinetics, and ionic diffusion, leading to reduced capacity and power limits, which affects vehicle performance and safety.
Innovation Solution
A battery heating device with a current collection plate (CCP) and heater layer design that utilizes resistive heating, featuring conductive materials and polymer compositions for efficient heat transfer and uniform temperature distribution across battery cells, incorporating thermal protectors and sensors for temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external air heating is used, then the battery can be heated, but the heating time becomes relatively long due to low thermal conductivity of air
Solution Approach 1:
The patent introduces a thermal conductive adhesive as an intermediary material between the heating element and battery cells. This adhesive has high thermal conductivity to facilitate efficient heat transfer from the heating element to the battery, while also providing electrical insulation. This resolves the contradiction by using a mediating substance that enables effective thermal coupling without the limitations of air heating.
2Productivity
If liquid heating system is used, then faster heating rate is achieved, but sealing issues and design challenges increase
Solution Approach 1:
The patent extracts the heating function from a complex liquid circulation system and implements it directly through a solid-state heating element with conductive adhesive. This eliminates the need for pumps, pipes, and seals associated with liquid heating systems, achieving fast heating rates through direct thermal conduction while significantly reducing system complexity.
Solution Approach 2:
The patent replaces the mechanical liquid circulation system with a solid-state heating element and conductive adhesive system. This substitution eliminates moving parts and fluid dynamics complexity while maintaining effective heat transfer through direct thermal contact, resolving the contradiction between heating rate and system complexity.
3Temperature
If electrothermal element heating is used, then heating can be provided, but non-uniform temperature distribution occurs between cells
Solution Approach 1:
The patent applies local quality by using individual heating elements for each battery cell or group of cells, with thermal conductive adhesive ensuring uniform heat distribution across each cell's surface. This localized approach with optimized thermal coupling material ensures uniform temperature distribution within and between cells, resolving the contradiction between providing heat and maintaining temperature uniformity.
4Temperature
If internal resistance heating is used, then heating can be generated, but system complexity and cost increase
Solution Approach 1:
The patent employs a dedicated heating element rather than relying on internal resistance heating of existing components. This self-service approach uses a purpose-built heating element with thermal conductive adhesive to generate and transfer heat efficiently, avoiding the system complexity and control issues associated with utilizing internal battery resistance for heating.
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 uniform and efficient heating, extending battery performance in cold climates, minimizing heater failure risk, and enhancing battery life by maintaining optimal cell temperatures and safety.
Implementation Method 1
A battery heating device with a current collection plate (CCP) and heater layer design that utilizes resistive heating
Implementation Method 2
featuring conductive materials and polymer compositions for efficient heat transfer and uniform temperature distribution across battery cells
Data Source
AI summary
A heating device, a resulting battery pack assembly, and the methods of making and using the same are provided. Such a battery pack assembly includes a plurality of battery cells, at least one current collection plate (CCP), and at least one heater layer. Each battery cell comprises two electrodes extending from a first side to a second side of the assembly. The CCP is disposed over a plurality of battery cells on the first side and/or the second side, is made of a first conductive material, and defines a plurality of first holes. Each first hole is disposed over a respective electrode. The CCP further includes at least one connection electrically connected with the respective electrode. The heater layer is disposed above the CCP, and includes a plurality of sections and each section corresponding to a respective battery cell. In each section the heater layer defines a second hole and includes a heating zone and a non-heating zone. The non-heating zone is disposed adjacent to an edge of the second hole. The heating zone includes a second conductive material embedded in a polymer composition, and the non-heating zone is made of the polymer composition. The second hole and a respective first hole provide a venting path for the respective battery cell.