Battery Pack Heater Assembly Using Thermal Diffusing Plates
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Solution Overview
Problem
Existing battery packs with multiple battery modules face challenges in compactness and simplicity due to the need for multiple heaters, which complicates the structure and wiring, and can make it difficult to fit them in limited vehicle spaces, especially when using direct heating methods or external heaters that increase the pack's dimensions.
Innovation Solution
A battery pack configuration that includes thermal diffusing plates holding cylindrical batteries, a first chamber for cooling air, and a second chamber with a convection zone between the thermal diffusing plates and a heater, allowing for efficient heating of multiple modules with a single heater, thus simplifying the structure and maintaining compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple battery modules are mounted in a battery pack to increase electrically-driven travel distance, then the travel distance is improved, but the device complexity increases due to the need for multiple heaters
Solution Approach 1:
Multiple battery modules are merged into a single integrated battery pack structure, sharing common heating and cooling systems. The battery holder integrates multiple battery housing spaces with shared thermal management components, reducing the number of independent heaters needed while maintaining the ability to heat multiple modules effectively.
2Temperature
If heaters are directly fixed to the battery holder or attached to each cylindrical battery, then heating efficiency is improved, but the structure becomes complicated and wiring is increased
Solution Approach 1:
The battery holder serves multiple functions: it mechanically supports the cylindrical batteries, provides thermal management through integrated heating elements, and acts as a structural framework. The heater is positioned to serve multiple battery modules simultaneously, reducing the total number of heating components and simplifying wiring requirements.
3Temperature
If the heater is disposed outside the battery pack to heat batteries through air space, then the heating coverage is improved, but the battery pack dimension increases
Solution Approach 1:
The heater is nested within the battery pack structure, specifically positioned in the battery holder among the battery modules. This internal placement allows the heater to radiate heat to multiple batteries through the confined space, achieving effective heating coverage without increasing the external dimensions of the battery pack.
4Area of stationary object
If a number of battery modules are mounted in a relatively small size, then the space utilization is improved, but the battery pack becomes difficult to house in vehicle space due to compactness requirements
Solution Approach 1:
The battery modules are arranged in a three-dimensional configuration within the battery pack, utilizing vertical and lateral spaces efficiently. The battery holder creates multiple housing spaces that stack and arrange batteries in dimensions beyond a simple linear layout, maximizing space utilization while maintaining a compact external footprint suitable for vehicle installation.
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 configuration allows for efficient heating of multiple battery modules with a single heater, simplifying the battery pack design and maintaining compactness, enabling more modules to be fitted within the same space, thereby addressing the challenge of increased travel distance requirements in electric vehicles.
Implementation Method 1
The heater is disposed in the second chamber, and faces the respective thermal diffusing plates of the adjacent battery modules across a predetermined distance
Implementation Method 2
thermal diffusing plates hold the cylindrical batteries
Implementation Method 3
Cooling air to cool each of the cylindrical batteries is introduced into the first chamber
Data Source
AI summary
A battery pack including adjacent battery modules is provided. Each of the battery modules includes one or more cylindrical batteries; a thermal diffusing plate holding the one or more cylindrical batteries; and a first chamber configured to distribute cooling air to cool each of the one or more cylindrical batteries. The battery pack further includes a second chamber provided between the adjacent battery modules, each of the respective thermal diffusing plates of the adjacent battery modules forming at least part of a wall of the second chamber; and a heater provided in the second chamber, the heater facing the respective thermal diffusing plates of the adjacent battery modules.