Battery Module Heating Wire Layout for Uniform Cell Warm-Up
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Solution Overview
Problem
Conventional battery systems face challenges in efficiently managing temperature, especially at low temperatures, which can lead to lithium plating and premature aging of battery cells due to uneven thermal influences, requiring effective active heating solutions.
Innovation Solution
A battery module incorporating an electrical resistive heating element with varying cross sections and laying densities to provide intensive heating, ensuring thermally conductive contact with battery cells, and potentially integrating the heating element into a bracing belt for space efficiency and adhesive bonding for secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a uniform heating element is used across all battery cells, then the heating element structure is simple, but thermal disparities between different battery cell positions cannot be addressed
Solution Approach 1:
The heating element features variable laying density with higher density at terminal positions and lower density in intermediate positions. This local differentiation allows the heating element to provide intensified heating where thermal losses are greatest (terminal cells) while maintaining adequate heating in intermediate cells, thereby achieving temperature uniformity across all cells without requiring multiple separate heating elements.
2Power
If heating wire cross section is reduced to increase heating power, then heating efficiency improves, but wire resistance to breakage decreases
Solution Approach 1:
The heating wire cross-section is varied along its length to match the local heating requirements. In terminal heating areas where high heating power is needed, the wire has a smaller cross-section (higher resistance per unit length). In intermediate areas where less heating is needed, the wire has a larger cross-section (lower resistance per unit length), which also provides greater mechanical strength where the wire is less critical for thermal performance.
3Device complexity
If heating element is integrated into bracing belt, then space is saved and structure is simplified, but the bracing belt must perform both structural and heating functions
Solution Approach 1:
The heating element is integrated into the bracing belt structure, combining the mechanical support function of the bracing belt with the thermal management function of the heating element. This merging eliminates the need for a separate heating component, simplifies the overall structure, and ensures that both functions are performed by a single integrated component without compromising either function's effectiveness.
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
This solution effectively addresses thermal disparities within battery modules, preventing premature throttling and damage by ensuring consistent heating, thereby enhancing the availability and longevity of battery cells across varying temperature conditions.
Implementation Method 1
an electrical resistive heating wire (31) that heats the surroundings when flowed through by current
Implementation Method 2
Both heating areas of the electrical resistive heating element are in thermally conductive contact with outer surface regions of the battery cells
Data Source
AI summary
A battery module having a multiplicity of battery cells in thermally conductive contact with an electrical resistive heating element that comprises an electrical resistive heating wire, wherein a first area of the heating element comprises an electrical resistive heating wire with a first cross section, which is in thermally conductive contact with a first outer surface region of battery cells, and wherein a second area of the heating element, which has a resistive heating wire with a second cross section different from the first cross section, is in thermally conductive contact with a second outer surface region of battery cells, and/or wherein the resistive heating element has a first area with a first laying density of electrical resistive heating wire that is in thermally conductive contact with first outer surface regions of battery cells and comprises a second area that has a second laying density, different from the first laying density, of the electrical resistive heating wire and is in thermally conductive contact with second outer surface regions of battery cells.