Battery Module Resistive Heating for Fast Low-Temperature Charging

Solution Overview

Problem

Conventional battery systems face challenges in efficiently managing temperature, particularly at low temperatures, which can lead to lithium plating and hinder energy intake, and require space-efficient and effective heating solutions.

Innovation Solution

A battery module with integrated electrical resistive heating elements, such as flexible printed circuits or heating mats, directly contacts battery cell surfaces for uniform and flexible heating, accommodating volume changes and reducing installation space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a fluid-based temperature control system is used, then temperature control capability is provided, but installation space is consumed and heating speed is reduced

Engineering Contradiction:

Improvetemperature control capabilityVSAvoidinstallation space

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

The patent replaces the mechanical fluid circulation system with an electrical resistive heating element that converts electrical energy directly to thermal energy through Joule heating. This eliminates the need for pumps, channels, and fluid circulation infrastructure, significantly reducing installation space while maintaining temperature control capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention extracts the heating function from the fluid-based temperature control system and implements it as a separate, integrated resistive heating element. This allows the heating function to be provided independently without requiring the complex fluid circulation infrastructure.

Inventive Principle:

Principle #2Taking out (Extraction)

2Temperature

If a fluid-based temperature control system is used, then temperature control capability is provided, but heating speed is reduced

Engineering Contradiction:

Improvetemperature control capabilityVSAvoidheating speed

Core Design Contradiction:

TemperatureVSSpeed

Solution Approach 1:

The patent replaces the mechanical fluid circulation system with an electrical resistive heating element that converts electrical energy directly to thermal energy through Joule heating. This eliminates the need for pumps, channels, and fluid circulation infrastructure, significantly reducing installation space while maintaining temperature control capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention extracts the heating function from the fluid-based temperature control system and implements it as a separate, integrated resistive heating element. This allows the heating function to be provided independently without requiring the complex fluid circulation infrastructure.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If battery cells are operated at low temperatures, then energy intake is limited, but lithium plating risk increases

Engineering Contradiction:

Improveenergy intakeVSAvoidlithium plating risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary heating action by activating the resistive heating element before charging operations at low temperatures. This pre-heats the battery cells to an optimal temperature range, enabling safe and efficient energy intake while preventing lithium plating that would occur if charging proceeded directly at low temperatures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system monitors battery cell temperature and provides feedback control to the heating element. When temperature drops below the optimal charging range, the heating element is activated to maintain the temperature within the safe operating window, thereby preventing lithium plating while enabling continuous energy intake.

Inventive Principle:

Principle #23Feedback

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 fast, effective, and space-efficient temperature control, preventing lithium plating and ensuring efficient energy intake by directly heating critical battery cell regions.

Implementation Method 1

having an electrical resistive heating element... direct physical contact between the electrical resistive heating element and appropriate regions of the battery cell housing... fast and effective temperature control or heating

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS12418063B2Heated battery module

Publication Date: 2025.09.16 ROBERT BOSCH GMBH

AI summary

A battery module having a multiplicity of battery cells (14), in particular rechargeable lithium-ion battery cells that each have a battery cell housing (16), comprising a side surface that surrounds the inside of the cell, a bottom and a top surface, wherein the side surface and/or the bottom surface of the battery cell housings (16) are/is in physical contact with an electrical resistive heater (30).