Contact Bridge Heating for EV Storage Modules

Solution Overview

Problem

Existing storage modules for electric vehicles face challenges in efficiently heating storage cells at low temperatures, leading to reduced drive power, increased costs, weight, and energy losses due to the need for dedicated heating systems.

Innovation Solution

Incorporating temperature-dependent contact bridges with specific electrical resistance materials or mechanical designs that reduce resistance at high temperatures, allowing for self-heating of storage cells through current flow and efficient thermal energy transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a dedicated heating system is provided in the storage module, then the storage cells can be heated at low temperatures to maintain drive power, but the structural space, cost, and weight of the storage module increase

Engineering Contradiction:

Improvestorage cell temperatureVSAvoidheating system structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heating function is merged with the existing contact bridges that connect storage cells. The contact bridges are equipped with heating elements that utilize the existing structural components and current paths, eliminating the need for separate dedicated heating systems. This combines the connection function and heating function into a single integrated component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The contact bridges serve dual purposes: electrical connection between storage cells and heating elements. By making the contact bridges multi-functional, the patent eliminates the need for separate heating systems, reducing structural complexity while maintaining the ability to heat storage cells when needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If a dedicated heating system is provided in the storage module, then the storage cells can be heated at low temperatures to maintain drive power, but additional weight is added to the storage module

Engineering Contradiction:

Improvestorage cell temperatureVSAvoidstorage module weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The heating function is merged with the existing contact bridges that connect storage cells. The contact bridges are equipped with heating elements that utilize the existing structural components and current paths, eliminating the need for separate dedicated heating systems. This combines the connection function and heating function into a single integrated component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The contact bridges serve dual purposes: electrical connection between storage cells and heating elements. By making the contact bridges multi-functional, the patent eliminates the need for separate heating systems, reducing structural complexity while maintaining the ability to heat storage cells when needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If a dedicated heating system is operated, then the storage cells can be heated at low temperatures, but electrical energy losses increase and vehicle range decreases

Engineering Contradiction:

Improvestorage cell temperatureVSAvoidelectrical energy loss

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The contact bridges utilize the existing module current that flows through them during normal operation to generate heat. The heating effect is a byproduct of the current flow through the contact bridge resistance, eliminating the need for separate heating energy input. The system serves itself by using operational current for both electrical connection and heating purposes.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The electrical resistance in the contact bridges, which typically causes energy losses, is converted into a beneficial heating effect. The power dissipation that would normally be wasted as heat is intentionally utilized to warm the storage cells when needed, transforming an energy loss into a useful heating function.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 provides energy-, space-, weight-, and cost-efficient heating for storage modules, reducing the need for dedicated heating systems while minimizing power losses at high temperatures and ensuring rapid heat-up at low temperatures.

Implementation Method 1

the contact bridge can provide relatively high electrical resistance... internal losses in the storage module can be restricted... can automatically be heated by the currents between the storage cells

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS10971772B2Storage module having heating measures

Publication Date: 2021.04.06 BAYERISCHE MOTOREN WERKE AG

AI summary

A storage module stores electrical energy. The storage module has a first storage cell and a second storage cell, each having a positive terminal and a negative terminal. The storage module includes a contact bridge, which connects one terminal of the first storage cell to one terminal of the second storage cell in an electrically conductive manner. The contact bridge is designed to reduce an electrical resistance between the electrically connected terminals of the first storage cell and of the second storage cell with rising temperature.