Battery Module Thermal Layer for Cold Start and Overheat Control
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Solution Overview
Problem
Battery modules used in hybrid and electric vehicles can experience overheating during operation and may be cold during start-up or in start-stop conditions, leading to improper functioning.
Innovation Solution
A thermal device comprising a non-metallic material layer that conducts heat and electricity, paired with metallic and plastic layers, which is disposed around battery cells to regulate temperature through heating and cooling mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If battery modules operate during cold start or start-stop conditions, then the battery can provide power, but the battery temperature is too low causing improper functioning
Solution Approach 1:
The patent converts the harmful cold temperature condition into a beneficial heating opportunity by using the battery's own current flow to generate heat through resistive heating in the graphite layer, thereby warming the battery to its optimal operating temperature range
Solution Approach 2:
The battery system performs self-heating by utilizing its own operational current to warm itself up during cold start conditions, eliminating the need for external heating systems
2Productivity
If battery modules operate continuously, then power output is maintained, but the battery modules overheat leading to improper operation
Solution Approach 1:
The patent changes the thermal properties of the battery system by introducing a graphite layer with high thermal conductivity that can dynamically adjust heat distribution, allowing the battery to maintain optimal temperature during continuous operation
Solution Approach 2:
The graphite layer acts as an intermediary thermal management component between the battery cells, facilitating efficient heat dissipation and maintaining temperature balance during continuous operation
3Temperature
If a thermal device is added to regulate battery temperature, then temperature control is improved, but device complexity increases
Solution Approach 1:
The patent merges the thermal management function with the existing battery structure by integrating the graphite layer directly into the battery assembly, eliminating the need for separate complex thermal management systems
Solution Approach 2:
The graphite layer serves multiple functions simultaneously: it acts as a current collector, provides structural support, and performs thermal management, thereby reducing overall device complexity while achieving temperature control
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 thermal device effectively heats battery modules at cold start and during start/stop operations, while preventing overheating during normal operation, thereby ensuring proper functioning and extending the lifespan of the battery modules.
Implementation Method 1
a first layer of a non-metallic material that is a good conductor of heat and electricity
Implementation Method 2
the metallic material generates infrared radiation that heats the at least one of the N cells
Implementation Method 3
current flows through the first layer and heats the first layer and the metallic material
Data Source
AI summary
A thermal device comprises a first layer of a non-metallic material that is a good conductor of heat and electricity, that includes a first terminal and a second terminal, and that has a first surface and a second surface; a metallic material disposed on the first surface of the first layer; a first plastic layer disposed on the metallic material; and a second plastic layer disposed on the second surface of the first layer. The first plastic layer and the second plastic layer include a plastic material that is a good conductor of heat.