Sealed Battery Module Thermal Layout for Faster Startup Heating
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Solution Overview
Problem
Existing battery module thermal regulation systems, such as those described in Chinese Patent No. 2078000824, are inefficient due to heating elements being in thermal contact with a small surface area of cooling plates, leading to prolonged activation times and unsuitability for applications with stringent startup requirements.
Innovation Solution
A system comprising a housing with a heating pad and a cooling plate, where the heating pad is in direct thermal contact with the battery cells via a gap pad, and the cooling plate directs coolant through channels to efficiently manage temperature, with a controller activating heating or cooling based on battery cell temperature thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If heating elements are placed on cooling plates with small surface area contact, then device complexity is reduced, but heating time and startup duration are extended
Solution Approach 1:
The patent introduces a thermal conductive adhesive layer as an intermediary substance between the heating element and cooling plate. This adhesive layer fills microscopic gaps and irregularities at the interface, creating effective thermal contact without requiring complex mechanical pressure systems or large surface areas. The adhesive mediator enables efficient heat transfer while maintaining simple device structure and reducing startup time.
2Ease of manufacture
If heating elements are in thermal contact with small surface area of cooling plate, then manufacturing is simplified, but thermal energy transfer efficiency is reduced
Solution Approach 1:
The patent changes the thermal contact parameter by introducing a thermal conductive adhesive layer with high thermal conductivity. This parameter change allows the heating element to efficiently transfer thermal energy to the cooling plate through the adhesive interface, achieving effective heat transfer without requiring large contact surface areas or complex assembly procedures.
3Device complexity
If heating elements are positioned on cooling plates, then device structure is simplified, but temperature control precision is reduced
Solution Approach 1:
The thermal conductive adhesive layer serves as a mediator that enables precise temperature control by ensuring uniform heat distribution across the heating element interface. The adhesive fills gaps and creates consistent thermal contact, allowing accurate temperature regulation without requiring complex positioning mechanisms or large surface area contacts.
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 configuration reduces startup time and enhances thermal energy transfer efficiency, allowing the battery module to maintain optimal temperature ranges and prevent damage, thus improving operational performance and longevity.
Implementation Method 1
a heating pad comprised of a heating element configured to raise a temperature of the plurality of battery cells
Implementation Method 2
a cooling plate configured to lower the temperature of the plurality of battery cells, the cooling plate including a coolant channel configured to direct coolant through at least part of the cooling plate
Implementation Method 3
a coolant channel configured to direct coolant through at least part of the cooling plate
Data Source
AI summary
A battery module includes a housing, assembled from a first side wall, a second side wall, a first end plate, and a second end plate, is configured to support a plurality of battery cells. The battery module also includes a heating pad and a cooling plate that are configured to regulate a thermal state of the plurality of battery cell. The heating pad is disposed substantially adjacent to the plurality of battery cells and the cooling plate is disposed adjacent to the heating pad opposite the plurality of battery cells. A controller associated with the battery module is configured receive an indication of battery temperature and active one of the heating pad or the cooling plate based at least on the battery temperature of the plurality of battery cells.