Prismatic Battery Heating Device with Flexible Hinge Connectors

Solution Overview

Problem

Existing high-voltage battery modules for electric vehicles face challenges in integrating heating elements cost-effectively, as positioning flexible heating foils between battery cells is costly and complex.

Innovation Solution

A heating device with two sheet-shaped heating elements and flexible connecting elements that can be easily mounted on the battery cell housing, allowing for hinge-like connection and energization, ensuring efficient heating without additional insulation or spacer elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If flexible heating foils are positioned between battery cells, then heating function is achieved, but manufacturing cost and complexity increase

Engineering Contradiction:

Improvebattery cell temperatureVSAvoidheating device integration complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heating elements are integrated directly into the cell housing structure, merging the heating function with the existing mechanical structure. This eliminates the need for separate flexible heating foils and their complex positioning, thereby reducing device complexity while maintaining the heating function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cell housing itself serves as the mounting structure for the heating elements, eliminating the need for additional insulation or spacer elements. The housing structure provides both mechanical support and thermal pathways, allowing the system to serve multiple functions with a single component.

Inventive Principle:

Principle #25Self-service

2Temperature

If flexible heating foils are positioned between battery cells, then heating function is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvebattery cell temperatureVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The heating elements are integrated directly into the cell housing structure, merging the heating function with the existing mechanical structure. This eliminates the need for separate flexible heating foils and their complex positioning, thereby reducing device complexity while maintaining the heating function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The heating elements are designed as simple integrated components rather than expensive flexible foils requiring precise positioning. This simplification reduces manufacturing cost while maintaining adequate heating performance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Temperature

If heating elements are integrated into battery module, then heating function is achieved, but structural complexity increases

Engineering Contradiction:

Improvebattery cell temperatureVSAvoidstructural complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cell housing itself serves as the mounting structure for the heating elements, eliminating the need for additional insulation or spacer elements. The housing structure provides both mechanical support and thermal pathways, allowing the system to serve multiple functions with a single component.

Inventive Principle:

Principle #25Self-service

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 solution enables simple, cost-effective integration of heating elements within the battery module, ensuring efficient heating and maintaining a homogeneous temperature distribution across the battery cells, thereby enhancing drive power at low external temperatures.

Implementation Method 1

two sheet-shaped heating elements for arrangement on two opposite lateral outer sides of a cell housing of the battery cell... connecting elements which connect the heating elements mechanically and electrically... for connecting to an energy source which makes available a heating current

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11335965B2Heating device for a prismatic battery cell of a high-voltage battery of a motor vehicle, battery cell, battery module, high-voltage battery and motor vehicle

Publication Date: 2022.05.17 BAYERISCHE MOTOREN WERKE AG

AI summary

A heating device for a prismatic battery cell of a high-voltage battery of a motor vehicle includes two sheet-shaped heating elements to be arranged on two opposite lateral outer sides of a cell housing of the battery cell, and two connecting elements to be arranged on a housing cover of the cell housing. The connecting elements are electrically connected to terminals of the two heating elements. The connecting elements are flexibly formed, at least in certain regions, and as a result the heating elements are connected in a hinge-like manner. The heating device can be arranged by arranging the first heating element on the first lateral outer side of the cell housing, swinging the second heating element over the housing cover, and arranging the second heating element on the second lateral outer side on the cell housing.