Cylindrical Battery Cell Layout With PTC Heating for Cold Charging

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery pack designs for light electric vehicles (LEVs) face challenges in efficiently and cost-effectively heating battery packs, especially in cold conditions, due to high implementation costs and complexity of liquid phase change thermal management systems.

Innovation Solution

A battery arrangement featuring a planar array of at least 16 generally cylindrical battery cells surrounded by a case with spacing elements, and utilizing a Positive Temperature Coefficient (PTC) heating film (PTCHF) to efficiently heat the battery pack, eliminating the need for liquid-based thermal management systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If liquid phase change thermal management systems are used for battery heating, then heating effectiveness is improved, but implementation cost and system complexity increase significantly

Engineering Contradiction:

Improvebattery temperatureVSAvoidthermal management system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent extracts the heating function from the complex liquid phase change thermal management system and implements it through a simplified resistive heating element integrated directly into the battery pack structure. This separates the heating capability from the cumbersome cooling infrastructure, achieving heating effectiveness without the associated complexity and cost.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical liquid phase change system with an electrical resistive heating system. Instead of using mechanical pumps, phase change materials, and complex thermal management infrastructure, the invention uses electrical resistance heating elements that can be directly controlled and integrated into the battery pack, eliminating the need for bulky mechanical components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Temperature

If liquid phase change thermal management systems are used for battery heating, then heating effectiveness is improved, but implementation cost increases

Engineering Contradiction:

Improvebattery temperatureVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent employs inexpensive resistive heating elements and standard electrical components instead of expensive phase change materials and complex thermal management hardware. These simpler components are cheaper to manufacture and integrate, reducing overall system cost while maintaining adequate heating performance for the application.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the thermal management approach from passive phase change materials to active electrical heating, allowing for lower cost implementation. By using readily available electrical components and simple resistive heating elements, the system achieves temperature control at a fraction of the cost of liquid phase change systems.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If battery cells are arranged in planar array with spacing elements, then thermal management and safety are improved, but space utilization decreases

Engineering Contradiction:

Improvebattery pack safetyVSAvoidbattery pack volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent segments the battery pack into modular cells with spacing elements between them. This segmentation creates thermal zones and safety barriers without requiring excessive space, as the spacing is minimized to only what is necessary for thermal management and safety. The modular approach allows efficient packing while maintaining reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies spacing elements selectively between battery cells rather than uniformly throughout the entire pack. The spacing is concentrated in areas where thermal management and safety are most critical, allowing maximum space utilization in other areas. This localized approach maintains reliability while minimizing overall volume impact.

Inventive Principle:

Principle #3Local quality

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 proposed solution effectively heats the battery pack from -20°C to 10°C in one hour, ensuring safe charging in cold environments while reducing costs and complexity compared to traditional liquid phase change systems.

Implementation Method 1

utilizing a Positive Temperature Coefficient (PTC) heating film (PTCHF) to efficiently heat the battery pack

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20250070363A1Enhanced battery cell arrangement

Publication Date: 2025.02.27 EXPION360 LLC

AI summary

An enhanced battery arrangement is provided, including a plurality of generally cylindrical battery cells positioned side by side in a planar array, the plurality of generally cylindrical battery cells including at least 16 generally cylindrical battery cells and a case surrounding at least a portion of the plurality of generally cylindrical battery cells. The case includes spacing elements abutting multiple cylindrical battery cells.