Embedded Heater Thermal Interface for In-Place Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The performance and lifespan of rechargeable batteries in electric vehicles are affected by temperature fluctuations, and existing thermal management systems face challenges in efficient and uniform curing of thermal interfacing materials, leading to suboptimal heat dissipation and prolonged curing times.
Innovation Solution
A thermal interfacing assembly is developed, featuring a cooling plate with an electrically insulating and thermally conductive material, embedded heaters with varying resistance, and a polymeric base, allowing for in-place curing of the thermal interfacing material, which is accelerated by external jumpstarting and controlled heating, ensuring efficient heat transfer and reduced curing cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional external curing methods are used for thermal interfacing material, then curing can be initiated, but curing time is prolonged and uniformity is poor
Solution Approach 1:
The heating element is integrated directly into the thermal interfacing assembly, merging the curing function with the thermal management structure. This allows simultaneous heating of the entire interface area, achieving uniform curing throughout the material while reducing total curing time compared to external heating methods.
Solution Approach 2:
The heating element is pre-positioned within the assembly structure before final assembly, allowing curing to begin immediately when power is applied. This preliminary positioning ensures that heat is distributed uniformly from the start of the curing process, eliminating the need for external positioning and adjustment during curing.
2Productivity
If high temperature is used for curing thermal interfacing material, then curing speed increases, but thermal damage to battery components may occur
Solution Approach 1:
The heating system uses variable resistance elements that allow dynamic adjustment of heating power. The resistance can be changed during the curing process to optimize heating rate at different stages, enabling fast curing when needed while preventing overheating and thermal damage to sensitive battery components.
Solution Approach 2:
The curing process utilizes changes in electrical resistance with temperature to automatically regulate heating intensity. As the material cures and temperature rises, resistance changes provide natural feedback control, maintaining optimal curing temperature without requiring external intervention or risking thermal damage.
3Manufacturing precision
If complex curing control systems are implemented, then curing precision improves, but device complexity increases
Solution Approach 1:
The heating element's inherent variable resistance provides self-regulating curing control without requiring external sensors or complex control circuits. The material's own electrical properties are utilized to automatically modulate heating, achieving precise curing control while maintaining simple device architecture.
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 thermal management of battery modules by ensuring efficient heat dissipation and accelerated curing of the thermal interfacing material, improving battery performance and lifespan while reducing cycle time and operational complexity.
Implementation Method 1
The first embedded heater includes an electrically-conductive portion and a resistive portion, the resistive portion being configured to have a resistance that varies with at least one of a temperature and an electric current. The first embedded heater is employed to at least partially induce in-place curing of the thermal interfacing material.
Implementation Method 2
The thermal interfacing material is configured to be electrically insulating and thermally conductive.
Data Source
AI summary
A thermal interfacing assembly for use in a power module having at least one battery module and a cooling plate, and corresponding method of forming the thermal interfacing assembly. The thermal interfacing material is deposited over a first surface of the cooling plate such that the thermal interfacing material conforms to the shape of the first surface. The thermal interfacing material is configured to be electrically insulating and thermally conductive. A first embedded heater is positioned adjacent to the thermal interfacing material. The first embedded heater includes an electrically-conductive portion and a resistive portion. The battery module is installed adjacent to the first embedded heater such that the first embedded heater is directly in contact with a first face of the battery module. The first embedded heater is employed to at least partially induce in-place curing of the thermal interfacing material.