Battery Heating Sheet Layout to Limit Gap-Region Overheating
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Solution Overview
Problem
In battery modules, heating sheets used for preheating in low-temperature environments can suffer from overheating and potential damage or fire when used for extended periods due to localized heat buildup between battery cells, especially at chamfered edges and corners where attachment is challenging, leading to reduced heat productivity and increased weight with the use of thermally conductive adhesives.
Innovation Solution
A battery module design featuring a heating sheet with multiple heating units and connection units, where the connection units have a lower heat productivity per unit area than the heating units, utilizing insulating films and conductive wires with reduced routing density or larger cross-sectional areas to minimize heat transfer across gap regions between battery cells, preventing overheating and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the heating sheet operates for a long time in low-temperature environments, then the preheating function is maintained, but the heating sheet may be burnt out or even cause fire due to localized heat buildup
Solution Approach 1:
The patent applies local quality by differentiating the heat productivity between heating units and connection units. Heating units have higher heat productivity to effectively preheat battery cells, while connection units have lower heat productivity to prevent localized heat buildup in gap regions. This spatial differentiation of thermal properties resolves the contradiction between maintaining preheating function and preventing overheating damage during long-term operation.
2Temperature
If thermally conductive adhesives are used to attach the heating sheet, then heat transfer is improved, but the weight of the battery module increases
Solution Approach 1:
The patent extracts and eliminates the thermally conductive adhesive layer from the heating sheet structure. Instead of relying on adhesives for thermal conduction, the design uses direct contact between heating units and battery cell surfaces, combined with optimized heat distribution through connection units. This removal of unnecessary material reduces weight while maintaining effective heat transfer to where it is needed.
3Area of stationary object
If the heating sheet is attached to chamfered edges and corners of battery cells, then heating coverage is improved, but attachment is challenging and heat productivity is reduced
Solution Approach 1:
The patent segments the heating sheet into distinct heating units and connection units. Heating units are designed to attach to flat surfaces of battery cells where attachment is reliable, while connection units bridge the gap regions between adjacent cells. This segmentation allows the system to achieve comprehensive heating coverage without requiring difficult attachment to chamfered edges and corners, maintaining both coverage and manufacturing ease.
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 design effectively reduces the risk of overheating and damage to the heating sheet by limiting heat productivity across gap regions, maintaining efficient heating while avoiding the need for thermally conductive adhesives, thus enhancing the battery module's reliability and energy density.
Implementation Method 1
a heating unit may include an insulating film and a heating wire laid on the insulating film
Implementation Method 2
the outflow end of the heating unit may be electrically coupled with the inflow end of an adjacent heating unit through the first conductive wire
Implementation Method 3
a heating unit may include an insulating film and a heating wire laid on the insulating film
Data Source
AI summary
A heating sheet and a battery module are provided. The battery module includes multiple battery cells and a heating sheet. The heating sheet includes multiple heating units and multiple connection units, and two adjacent heating units are coupled with each other through a connection unit. One heating unit may be attached to a side wall of one battery cell, and the connection unit corresponds to the gap region.