Folded Battery Cell Casing With Integrated Heater and Insulation

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Solution Overview

Problem

Current methods for producing battery cell casings with integrated heaters are costly and inefficient, particularly in modular battery structures where electrical insulation is necessary to prevent short-circuits, and existing heating solutions for energy storage devices are often ineffective due to their distance from the battery cells.

Innovation Solution

A method involving a layer-type planar cell heater integrated into the cell casing, where the heater is applied to a metallic layer and folded to form the casing, allowing for effective heating while maintaining electrical insulation and reducing the risk of damage during production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate electrically insulating film or lacquering is used to insulate battery cells, then electrical insulation is achieved, but production cost increases and fault detection becomes more difficult

Engineering Contradiction:

Improveelectrical insulationVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the electrical insulation function with the cell casing structure itself by applying the insulating layer directly to the casing surface, eliminating the need for separate insulating films or lacquering processes. This integration reduces production steps and costs while maintaining reliable electrical insulation between cells.

Inventive Principle:

Principle #5Merging (Combining)

2Use of energy by stationary object

If a heater is placed on the module or storage device level, then heating capability is provided, but effectiveness is reduced due to distance from battery cells

Engineering Contradiction:

Improveheating capabilityVSAvoidheating effectiveness

Core Design Contradiction:

Use of energy by stationary objectVSReliability

Solution Approach 1:

The patent implements heating elements directly integrated into the cell casing structure, allowing localized heating at the cell level rather than relying on distant module-level heaters. This ensures effective heat transfer to the battery cell while maintaining energy efficiency.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If deep drawing is used to produce cell casings, then casing formation is achieved, but integration of planar cell heater becomes difficult and mechanical stress on heater increases

Engineering Contradiction:

Improvecasing formationVSAvoidheater integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Instead of forming the casing through deep drawing and then attempting to integrate a planar heater, the patent inverts the approach by first creating a flat casing structure and then folding it into the final three-dimensional configuration. This allows the planar cell heater to be applied to the flat surface before folding, minimizing mechanical stress and simplifying integration.

Inventive Principle:

Principle #13The other way round (Inversion)

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 approach enables cost-effective and efficient heating of battery cells, ensuring effective electrical insulation and preventing short-circuits, while allowing for easy integration and minimal mechanical stress on the heater, thus enhancing the heating capability and reliability of the battery cell casing.

Implementation Method 1

a layer-type planar cell heater is applied to a flat side of a 'first' metallic layer

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a composite stack, which has at least the first metallic layer and the cell heater, is folded

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

an electrical insulation of the battery cells from one another is necessary to avoid short-circuits between the battery cells

Methodology Applied

Scientific EffectElectrical insulation: Conduction (electrical)

Data Source

PatentUS20230378563A1Production of a Cell Casing of a Battery Cell, and Cell Casing

Publication Date: 2023.11.23 BAYERISCHE MOTOREN WERKE AG

AI summary

A method for producing a cell casing for a battery cell having an integrated cell heater includes applying a cell heater to a first side of a first metallic layer, and, after the applying, folding a composite stack comprising at least the first metallic layer and the cell heater, such that a second side of the first metallic layer forms an inside of the cell casing. A battery has a plurality of battery cells which each have a cell casing of this kind, where the second metal layers of the cell casings are electrically interconnected. An electrically operated vehicle has at least one battery including at least one battery cell which comprises a cell casing of this kind and/or a battery of this kind.