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Innovative balancing, heating and temperature sensing element for automotive batteries

Proceedings article published in 2013 by R. Filimon, J. Grosch, E. Teuber, M. Jank, V. Lorentz, M. Wenger, M. Giegerich, M. März, L.: Frey
This paper is available in a repository.
This paper is available in a repository.

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Preprint: policy unknown
Question mark in circle
Postprint: policy unknown
Question mark in circle
Published version: policy unknown

Abstract

Electrically driven vehicles are still a rarity on our streets, mainly due to the high costs of these cars compared to conventional ones. The most expensive part is the battery pack with its management electronics. By reducing these costs, electrical vehicles will gain attractiveness. The novel concept for the integration of temperature sensing, balancing, and heating elements presented in this paper allows a significant reduction of the final battery pack costs. The proposed integration concept provides a balancing resistor, a heating element, and a printed temperature sensor together on the same flexible substrate. This foil can be easily integrated between battery cells or in existing module frames, thus reducing the development time for new modules and packs. By adding a controller and switches, the obtained smart battery cell can handle elementary functions (e.g., temperature sensing) by itself. The wiring and contacting effort is reduced to a contactless two wire communication bus. The temperature sensor is printed directly onto a plastic substrate, featuring low thickness compared to conventional discrete temperature sensors (e.g., NTC). Furthermore, printed electronics are suitable for high-volume production at very low costs. In the prototype presented here, two different resistors are placed on the same substrate. One resistor is used for passive balancing. The other acts as a heating element to heat up the battery cell homogeneously directly at its core (e.g., in cold start situations). There is no need for an external heating source, thus further reducing the overall costs without renouncing to functionality. The provided concept allows a significant reduction of production and development costs of battery packs. New printed electronics technology allows a cost effective high volume manufacturing by printing the temperature sensor, the balancing resistor and even a high power heating element at a time. By easily adapting the geometry to new designs, development time is saved. In later stages also switching elements and logic circuitry can be integrated. This optimizes the functionality, minimizes the time to market and reduces the overall costs of the whole battery pack.