Integrated Heater Thermal Interface Material for Battery Packs
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Solution Overview
Problem
Electrified vehicle batteries require effective thermal management to maintain optimal performance, as they need to be cooled or heated depending on conditions, but existing systems lack efficient and integrated solutions for heating battery cells during cold conditions.
Innovation Solution
A battery thermal management system that integrates a thermal interface material with a heater element, such as a resistive heater wire, which is embedded, bonded, or printed on the thermal interface material, and is actuated by a control system to heat battery cells when the temperature drops below a predefined threshold, ensuring efficient heat generation and application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate heater system is used to heat battery cells during cold conditions, then the heating function is achieved, but the device complexity and space requirements increase
Solution Approach 1:
The heater element is integrated directly into the thermal interface material that contacts the battery cell. This merging of the heating function with the existing thermal interface component eliminates the need for separate heater assemblies, reducing overall system complexity while maintaining effective heating capability during cold conditions
Solution Approach 2:
The thermal interface material serves multiple functions: it provides thermal contact between components and simultaneously incorporates the heating function through the integrated heater element. This multi-functionality reduces the number of separate components needed in the thermal management system
2Device complexity
If a thermal interface material with integrated heater element is used, then the system complexity is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The heater element is positioned specifically within the thermal interface material at the location where heat is most needed - directly adjacent to the battery cell. This localized placement ensures efficient heat transfer to the battery while simplifying the overall system architecture, and the integration methods (embedding, bonding, or printing) are designed to achieve the required precision through targeted manufacturing processes
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 system effectively heats battery cells during cold conditions, maintaining their performance and extending the operational range of electrified vehicles by ensuring consistent temperature conditions.
Implementation Method 1
a heater element integrated with the thermal interface material... the heater element is a resistive heater wire
Implementation Method 2
a thermal interface material adjacent the battery cell... the thermal interface material is sandwiched between the battery cell and a second battery cell
Data Source
AI summary
A battery pack includes a battery cell, a thermal interface material adjacent the battery cell and a heater element integrated with the thermal interface material.