Integrated Battery Self-Heating Structure for Low-Temperature Charging
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Solution Overview
Problem
Existing self-heating circuits in battery packs are complex, reducing energy density and increasing production costs due to extensive wiring and electronic elements, which limits their performance in low-temperature environments.
Innovation Solution
A self-heating structure with a heating member and integrated connection lead, along with a control unit, forms a simplified self-heating circuit that is activated based on temperature, reducing the need for additional wiring and electronic components, and includes a passivation layer to prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional self-heating circuits are used with separate wiring and electronic elements, then the battery pack can achieve self-heating function, but the structural complexity and production cost increase
Solution Approach 1:
The patent merges the heating element and connection lead into a single integrated heating member. The connection lead is molded directly onto the heating body, combining two previously separate components (heating element and wiring) into one unified structure, thereby reducing wiring complexity while maintaining self-heating functionality
Solution Approach 2:
The heating member serves multiple functions simultaneously: it generates heat for self-heating, provides electrical connection through the molded connection lead, and acts as a structural component within the battery pack. This multi-functionality reduces the need for separate dedicated wiring and electronic elements
2Reliability
If traditional self-heating circuits with extensive wiring are used, then the battery pack can achieve self-heating function, but the energy density of the battery pack is reduced
Solution Approach 1:
By integrating the connection lead with the heating body into a single molded component, the overall volume occupied by heating-related materials is reduced. This frees up space within the battery pack that can be utilized for additional active materials, thereby improving energy density while preserving self-heating capability
Solution Approach 2:
The heating member采用 thin-film or flexible structure design, allowing it to occupy minimal space within the battery pack. The molded connection lead integrates seamlessly with the heating body, reducing the overall material quantity required for the self-heating system and increasing the proportion of active materials in the battery pack
3Reliability
If connection lead is separately wired to heating body, then the self-heating circuit can be formed, but the structural strength and working stability are reduced
Solution Approach 1:
The connection lead is molded directly onto the heating body, creating an integrated structure where the two components become mechanically unified. This molding process creates strong adhesion between the lead and heating body, eliminating weak points associated with separate wiring connections and significantly improving structural strength and working stability
Solution Approach 2:
The molded structure combines the heating body material with the connection lead material into a composite assembly. This integration creates a unified structure with enhanced mechanical properties, where the bond between lead and heating body is as strong as or stronger than the materials themselves, improving overall structural integrity
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 enhances the structural strength and stability of the heating member, improves energy density, reduces production costs, and ensures efficient self-heating while preventing overheating, thereby enabling reliable charging in low-temperature conditions.
Implementation Method 1
the control unit turns on the self-heating circuit, and the heating member is energized to produce a rapid thermal effect so as to achieve the self-heating inside the core pack
Data Source
AI summary
Disclosed in the present application is a self-heating structure and a battery pack including the same. The self-heating structure includes a heating member, including a heating body and a connection lead molded on the heating body, the connection lead being used for electrically connecting a positive electrode tab of a core pack or a negative electrode tab of the core pack, so that a self-heating circuit is formed by the heating member and the core pack; and a control unit, controlling an on/off switching of the self-heating circuit according to temperature of the core pack, the control unit being provided on the connection lead to integrate the control unit and the connection lead.