Integrated Battery Heater for Low-Temperature Runtime Stability
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Solution Overview
Problem
Rechargeable lithium-ion batteries in outdoor electronic devices experience significant impedance increases at low temperatures, leading to reduced discharge capacity and voltage drops, which can cause device brownouts and shorten runtime.
Innovation Solution
Integrate a heating element with the battery cells to maintain optimal operating temperatures, using a resistive heater path and a temperature control circuit to dynamically adjust heater voltage based on battery temperature, while incorporating a waterproof material to protect the battery from environmental moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heating element is integrated with the battery cells, then the battery can be warmed up to maintain optimal operating temperature, but the device complexity increases
Solution Approach 1:
The heating element is integrated directly with the battery cells by wrapping it around the battery pack, merging the thermal management function with the battery structure. This eliminates the need for separate heating components and reduces overall device complexity while maintaining the ability to warm the battery at low temperatures
Solution Approach 2:
The heating element serves multiple functions: it warms the battery at low temperatures, maintains optimal operating temperature during operation, and can be controlled through existing battery management circuits. This multi-functionality justifies the added complexity by providing comprehensive thermal management
2Reliability
If waterproof material is wrapped around the heating element and battery cells, then protection from water permeation is improved, but the device volume increases
Solution Approach 1:
A thin waterproof material is wrapped around the heating element and battery cells to provide protection from water permeation. The use of thin film materials provides adequate protection while minimizing the increase in battery pack volume
Solution Approach 2:
The waterproof material is integrated with the existing battery packaging structure, creating a composite protective layer that combines the structural packaging with water protection functionality, thereby avoiding significant volume increase
3Reliability
If the heating element is integrated physically with the battery cells, then the battery can be warmed up to prevent impedance increase, but the manufacturing complexity increases
Solution Approach 1:
The heating element is pre-wrapped around the battery cells before final assembly, and electrical connections are pre-established. This preliminary preparation simplifies the manufacturing process by reducing the number of steps required during final battery assembly
Solution Approach 2:
The heating element is designed to be self-contained and self-regulating, using existing battery management circuits to control its operation. This eliminates the need for separate control systems and simplifies manufacturing by reducing the number of components that need to be integrated
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
Maintains battery impedance and discharge capacity, preventing unwanted voltage drops and extending device runtime in low-temperature environments without compromising the device's compact form factor.
Implementation Method 1
The heating element includes a resistive heater path electrically coupled to the heater terminal and one of the first and second terminals of the connector. The resistive heater path of the heating element generates heat to warm the battery when a heater voltage is applied to the heater terminal.
Implementation Method 2
The heating element is in contact with at least a subset of the one or more rechargeable battery cells, e.g., is wrapped around an exterior of the one or more rechargeable battery. When the heating element is heated up, the battery is warmed up.
Data Source
AI summary
This application is directed to a battery having a heating element. A connector of the battery includes a first terminal, a second terminal, and a heater terminal. One or more rechargeable battery cells are electrically coupled to the first and second terminals of the connector. The heating element is in contact with a subset of the battery cells, and includes a resistive heater path that is electrically coupled to the first and heater terminals of the connector and generates heat to warm the battery when a heater voltage is applied to the heater terminal. A waterproof material is wrapped around an exterior of the heating element and battery cells and prevents ambient water from contacting the heater element and battery cells. The waterproof material includes an opening to allow at least the first and second terminals of the connector to be electrically coupled to a logic board.