Honeycomb Battery Module Potting for Uniform Cell Heating
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Solution Overview
Problem
High-voltage storage devices in electric vehicles face challenges in efficiently heating battery cells due to the temperature dependence of lithium-ion rechargeable batteries, particularly with high energy densities or manganese-rich cell chemistry, where traditional heating concepts require significant integration and clash with installation space, especially in honeycomb structures with round cells.
Innovation Solution
A thermally and electrically conductive potting compound is used to fill the interspaces between battery cells in a honeycomb structure, connected to an energy source via electrically conductive fixing elements and pole connections, ensuring a homogeneous current flow for uniform heating across the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional heating concepts are used for battery cells, then heating function is provided, but integration outlay is high and installation space is insufficient
Solution Approach 1:
The heating function is merged with the existing cooling system by integrating heating elements into the cooling plates. This allows both heating and cooling functions to be provided through a single integrated structure, reducing the overall integration outlay and installation space requirements while effectively managing cell temperature.
Solution Approach 2:
The cooling plates are designed to serve multiple functions: they act as both cooling structures and heating elements. By incorporating heating capability into the universal cooling plate design, the system can provide both heating and cooling functions without requiring separate dedicated structures, thereby reducing device complexity.
2Temperature
If heating structure is added to cooling system, then heating function is achieved, but installation space is insufficient
Solution Approach 1:
The heating elements are merged into the existing cooling plates, allowing both functions to share the same physical space. This integration eliminates the need for separate heating structures, thereby achieving the heating function without increasing installation space.
Solution Approach 2:
The heating elements are nested within the cooling plate structure. By placing heating components inside or within the existing cooling plate geometry, the system achieves multi-functionality without requiring additional external space, effectively solving the installation space constraint.
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 enables efficient and uniform heating of battery cells within the honeycomb structure, improving temperature management and performance by distributing heating power effectively across the cells, thereby enhancing the operational range of electric vehicles.
Implementation Method 1
The interspaces between the battery cells are filled with a thermally and electrically conductive potting compound
Implementation Method 2
The interspaces between the battery cells are filled with a thermally and electrically conductive potting compound
Implementation Method 3
The electrical resistance of the potting compound is chosen for example such that when current flows or upon connection to an energy source, a heating power of 10-60 W (preferably 20-40 W) per cell arises
Data Source
AI summary
A high-voltage accumulator module has a multiplicity of battery cells, the battery cells being arranged in a honeycombed parallel and series connection assembly. The gaps between the battery cells are filled with a thermally and electrically conductive potting compound. The battery cells are electrically insulated with respect to the potting compound. The potting compound is connected to an energy source via electrically conductive fixing elements that protrude into the potting compound and via two pole connections in such a way that a current flow through the potting compound which is as homogenous as possible is achieved. The two pole connections, for example in the form of metal plates, are preferably fastened to the potting compound over a large surface area and in close electrical contact therewith by way of the fixing elements. The fixing elements may protrude as deep as possible into the potting compound in the form of strips or pins and may contain barbs.