L-Shaped Heater Module for Battery Packs
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Solution Overview
Problem
Conventional heater modules for battery packs have low heating efficiency as they indirectly heat battery modules through the casing, and face challenges in accommodating a power source connection terminal without increasing the module's thickness or size.
Innovation Solution
A heater module design featuring a plate-like heater body with an L-shaped insulating holder and a power source connection terminal located in the bent arm portion, allowing direct heating of battery modules while maintaining the original thickness and size of the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the heater body is arranged inside the casing adjacent to the battery modules for direct heating, then heating efficiency is improved, but the battery pack size is reduced leaving insufficient space for the heater body and holder
Solution Approach 1:
The heater body is configured in a bent shape (L-shaped or U-shaped) to utilize three-dimensional space within the casing more effectively. By changing from a straight linear arrangement to a bent configuration, the heater can contact multiple surfaces of the battery modules simultaneously, achieving direct heating while fitting within the limited internal volume of the downsized battery pack.
2Length of stationary object
If the heater module is formed thinly to reduce size, then the module dimensions are reduced, but it becomes difficult to arrange the power source connection terminal without changing the thickness and size
Solution Approach 1:
The power source connection terminal is arranged in the bent portion of the L-shaped or U-shaped heater body configuration. This utilizes the lateral space created by the bent shape rather than requiring additional thickness. The terminal is positioned in the space occupied by the bent arm of the heater, allowing integration without increasing the overall module thickness.
Solution Approach 2:
The bent portion of the heater body serves multiple functions: it provides structural support for the heater element, enables the heater to contact multiple surfaces of the battery modules, and creates space for accommodating the power source connection terminal. This multi-functional design allows the same structural feature to solve both heating and electrical connection requirements.
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 design enhances heating efficiency by direct contact between the heater body and battery modules, prevents uneven temperature distribution, and ensures the power source connection terminal can be integrated without increasing the module's dimensions, even in limited spaces.
Implementation Method 1
a plate-like heater body that faces the heated surface of the object to be heated
Implementation Method 2
the battery modules are indirectly heated by heat conduction from the casing of the battery pack to the battery modules
Implementation Method 3
an L-shaped insulating holder including a module main surface to which the plate-like heater body is provided
Data Source
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AI summary
A heater module (22L, 22R) of the present invention is provided along a heated surface (13CLa) of an object to be heated (13CL, 13CR). The heater module includes: a plate-like heater body (34) that faces the heated surface of the object to be heated; an L-shaped member (31) including a module main surface (31m) to which the plate-like heater body is provided, and a bent arm portion (31c) bent with respect to the module main surface; and a power source connection terminal (35) provided in the bent arm portion and connected to the plate-like heater body.