A flexible thin film sensor mounting device for battery modules without disassembly

Abstract

This utility model relates to the field of battery module sensor installation technology, and discloses a flexible thin-film sensor installation device for battery modules that does not require disassembly. It is suitable for the outer surface of battery modules, wherein the battery module includes a cell, and comprises: a tensioning strap, which is mounted around the outside of the battery module; a structural component, which is nested on the surface of the tensioning strap, and has a through groove on the structural component, with the opening side of the groove facing outwards and the closed side of the groove facing the battery module; and a flexible thin-film sensor, which is sandwiched between the back of the groove and the surface of the cell, the flexible thin-film sensor being in close contact with the cell, and the radial pressure of the tensioning strap being transmitted to the surface of the flexible thin-film sensor through the structural component. This utility model solves the problems of inefficient sensor installation on existing modules, insufficient installation reliability under dynamic operating conditions, and monitoring distortion caused by air gaps between the cell and the sensor.

Description

Technical Field

[0001] This utility model relates to the field of battery module sensor installation technology, specifically a flexible thin-film sensor installation device for battery modules that does not require disassembly. Background Technology

[0002] Flexible thin-film sensors, as core components for battery module status monitoring, play an irreplaceable role in preventing thermal runaway and optimizing battery management systems by collecting real-time data on cell temperature, pressure, and expansion. Current mainstream installation methods include adhesive bonding, sandwich integration, and strap fixing. These technologies are an important foundation for achieving battery safety monitoring.

[0003] However, existing installation technologies have inherent defects: adhesive-bonded types may cause sensors to fall off due to softening of the adhesive layer in high-temperature environments; sandwich-integrated types are only suitable for newly produced modules, and already packaged modules require destructive disassembly and cannot be repaired; strap-fixed types cause pressure monitoring distortion due to air gaps between the straps and the battery cells, and the straps are prone to loosening and sensor displacement under vibration conditions. These structural defects severely restrict the reliability of monitoring data and the universality of application scenarios. Summary of the Invention

[0004] (a) Technical problems to be solved

[0005] To address the shortcomings of existing technologies, this utility model provides a flexible thin-film sensor installation device for battery modules that does not require disassembly. It features non-destructive installation, zero-gap monitoring, and resistance to vibration and displacement, solving the problems of inefficient sensor installation on existing modules, insufficient installation reliability under dynamic operating conditions, and monitoring distortion caused by air gaps between the battery cell and the sensor.

[0006] (II) Technical Solution

[0007] To achieve the aforementioned objectives of non-destructive installation, zero-gap monitoring, and vibration-resistant displacement, this utility model provides the following technical solution: a flexible thin-film sensor mounting device for a battery module that does not require disassembly, suitable for the outer surface of the battery module, wherein the battery module includes a battery cell, comprising:

[0008] A tightening strap is installed around the outside of the battery module;

[0009] A structural component, which is nested on the surface of the tightening strap, has a through groove, with the opening side of the groove facing outward and the closed side of the groove facing the battery module.

[0010] A flexible thin-film sensor is sandwiched between the back of the groove and the surface of the battery cell. The flexible thin-film sensor is in close contact with the battery cell, and the radial pressure of the tension band is transmitted to the surface of the flexible thin-film sensor through the structure.

[0011] Preferably, the structural component is made of a rigid material.

[0012] Preferably, the depth of the groove is greater than the thickness of the tightening band; the cross-section of the groove is a rectangular groove or a trapezoidal groove.

[0013] Preferably, the closed side of the groove has a planar structure, and the closed side of the groove is in close contact with the flexible thin film sensor.

[0014] Preferably, the tightening band is a steel cable tie.

[0015] Preferably, the battery module includes two limiting frames, which are symmetrically distributed at both ends of the battery module; the battery cells are clamped between the two limiting frames.

[0016] Preferably, the outer surface of the limiting frame is provided with a limiting groove, and the tightening strap is embedded in the limiting groove.

[0017] Preferably, the limiting frame is provided with limiting edges around its perimeter, and the battery cell is disposed in the groove formed by the limiting edges.

[0018] Preferably, a silicone pad is provided between the closed side of the groove and the surface of the battery cell, and the flexible thin-film sensor contacts the surface of the battery cell through the silicone pad.

[0019] (III) Beneficial Effects

[0020] Compared with the prior art, this utility model provides a flexible thin-film sensor mounting device that does not require disassembly of the battery module, which has the following advantages:

[0021] 1. This flexible thin-film sensor installation device for battery modules that does not require disassembly utilizes a design with a recessed clamping strap in the structural components. It allows for sensor installation on existing modules without disassembly, and, combined with the sensor sandwich arrangement between the closed side and the battery cell, overcomes the problems of high-temperature detachment in existing adhesive-based installations, the non-removable nature of sandwich-integrated installations, and the air gap issues of strap-fixed installations. This allows for sensor installation without module disassembly, while ensuring zero-gap contact between the sensor and the battery cell surface. Compared to existing technologies, it offers advantages such as reduced pressure signal attenuation, self-reinforcing clamping, small displacement under vibration conditions, low modification costs, removable maintenance, no impact from high-temperature environments, reliable installation, accurate signal, and strong adaptability.

[0022] 2. This flexible thin-film sensor installation device for battery modules that does not require disassembly involves adding mirror-distributed limiting frames at both ends of the outer side of the parallel-arranged battery cells. The outer surface of the limiting frame has a limiting groove, and the limiting frame is surrounded by limiting edges. The battery cells are placed in the grooves formed by the limiting edges. Therefore, the limiting frame is locked onto the outer surface of the battery cells, and the limiting groove restricts the movement of the tensioning strap in the vertical direction, ensuring that the accuracy of the measurement data will not be affected by the shifting of the strap when the battery cells expand. Compared with traditional methods, this design ensures both secure installation and measurement accuracy, and can be installed without disassembling the battery pack. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the complete structure of this utility model;

[0024] Figure 2 This is a top view of the structural component of this utility model under stress.

[0025] Figure 3 This is a schematic diagram of the new utility model structural component;

[0026] Figure 4 This is a schematic diagram of the limiting frame of this utility model;

[0027] Figure 5 This is a schematic diagram showing the installation position of the silicone pad in this utility model.

[0028] In the picture:

[0029] 1. Battery module; 11. Battery cell; 12. Limiting frame; 121. Limiting groove; 122. Limiting edge;

[0030] 2. Elastic band;

[0031] 3. Structural components; 31. Groove;

[0032] 4. Flexible thin-film sensor;

[0033] 5. Silicone pad. Detailed Implementation

[0034] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0035] Please see Figures 1-3 and Figure 5A flexible thin-film sensor mounting device for battery modules that does not require disassembly is disclosed. This device is suitable for monitoring the outer surface of a battery module 1. It mainly consists of three parts: a tension band 2 surrounding the outside of the battery module 1; a structural component 3 nested within the tension band 2, which has a through groove 31 with its open side facing outwards and its closed side facing the battery module 1; and a flexible thin-film sensor 4 sandwiched between the closed side of the groove 31 and the surface of the battery cell 11. A silicone pad 5 is provided between the closed side of the groove 31 and the surface of the battery cell 11. The flexible thin-film sensor 4 contacts the surface of the battery cell 11 through the silicone pad 5. By placing the silicone pad 5 between the structural component 3 and the battery cell 11, both the fit is enhanced, and mechanical pressure is buffered, protecting the sensor from damage. The radial pressure of the tension band 2 is transmitted through the structural component 3, allowing... The sensor and the surface of the battery cell 11 are tightly bonded, eliminating the need to disassemble the module. The sensor can be installed after the module is already assembled. With the sensor sandwich arrangement between the closed side and the battery cell 11, it overcomes the problems of high-temperature detachment of existing adhesive-based installations, non-removable sandwich-integrated installations, and air gaps in strap-fixed installations. This allows the sensor to be installed without disassembling the module, while ensuring zero-gap contact between the sensor and the surface of the battery cell 11. Compared with existing technologies, it has advantages such as reduced pressure signal attenuation, self-reinforcing clamping, small displacement under vibration conditions, low modification cost, detachable maintenance, no impact from high-temperature environments, reliable installation, accurate signal, and strong adaptability, achieving accurate monitoring. This design cleverly utilizes the mechanical structure to transmit pressure, ensuring both installation stability and the accuracy of monitoring data.

[0036] In this invention, the structural component 3 is made of a rigid material, which can effectively transmit the warp tension of the tensioning band 2 and absorb as little pressure as possible to ensure the accuracy of the data from the flexible thin-film sensor 4. The tensioning band 2 is a steel cable tie, which can transmit the expansion force of the battery cell 11 to the structural component 3 without attenuation. In contrast, rubber and fiber tensioning bands 2 will absorb deformation energy, causing pressure signal distortion. At the same time, the steel cable tie can provide high tensile strength to ensure that the tensioning band 2 will not break when the battery cell 11 expands, especially during the violent expansion before thermal runaway.

[0037] Please see Figures 1-3 The depth of the groove 31 is greater than the thickness of the tightening band 2. The cross-section of the groove 31 is a rectangular or trapezoidal groove to prevent the tightening band 2 from coming out of the groove 31. The closed side of the groove 31 is a planar structure to ensure that the closed side of the groove 31 is in close contact with the flexible thin film sensor 4, eliminating air gaps and making the results more accurate.

[0038] Please see Figure 4The battery module 1 includes two limiting frames 12, which are symmetrically distributed at both ends of the battery module 1. The battery cells 11 are clamped between the two limiting frames 12. The outer surface of the limiting frame 12 has a limiting groove 121 and a limiting edge 122 around the limiting frame 12. The battery cells 11 are placed in the groove formed by the limiting edge 122. Therefore, the limiting frame 12 is locked on the outer surface of the battery cells 11, and the limiting groove 121 restricts the movement of the tensioning strap 2 in the vertical direction, ensuring that when the battery cells 11 expand, the strap will not shift and affect the accuracy of the measurement data. Compared with the traditional method, this design ensures both a firm installation and measurement accuracy, and can be installed without disassembling the battery pack.

[0039] In summary, this flexible thin-film sensor mounting device for battery modules that does not require disassembly achieves three core advantages through the nesting of the clamping strap 2 in the groove 31 of the structural component 3, combined with the mirror-distributed limiting frame 12 at both ends: First, the sensor can be installed without disassembling the module, solving the problems of high-temperature detachment in traditional adhesive methods, non-removable sandwich structures, and gaps in strap-type structures; second, the cooperation between the limiting frame 12 and the limiting groove 121 ensures that the clamping strap 2 will not shift when the battery cell 11 expands, guaranteeing that the sensor and the battery cell 11 always have zero-gap contact; third, it comprehensively achieves multiple advantages such as accurate signal, reduced pressure attenuation, self-reinforcing clamping, small vibration displacement, convenient use, removable maintenance, and low cost, perfectly overcoming various defects of existing technologies.

[0040] During use, the installer first places the open side of the structural component 3 facing outwards and the closed side facing the surface of the battery cell 11. Then, the steel cable tie is placed into the middle groove 31 of the structural component 3, and the sensor is clamped between the closed side of the structural component 3 and the battery cell 11. The installation is convenient and the disassembly is easy. After installation, the sensor cable can be led to the outside through the gap of the module housing or by drilling to connect to the data acquisition unit.

[0041] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0042] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A flexible thin-film sensor mounting device for a battery module that does not require disassembly, suitable for the outer surface of a battery module (1), the battery module (1) comprising a battery cell (11), characterized in that, include: A tightening strap (2) is installed around the outside of the battery module (1); Structural component (3) is nested on the surface of the tightening band (2). A through groove (31) is provided on the structural component (3). The opening side of the groove (31) faces outward, and the closed side of the groove (31) faces the battery module (1). A flexible thin-film sensor (4) is sandwiched between the back of the groove (31) and the surface of the cell (11). The flexible thin-film sensor (4) is in close contact with the cell (11). The radial pressure of the tension band (2) is transmitted to the surface of the flexible thin-film sensor (4) through the structural member (3).

2. The flexible thin-film sensor mounting device for a battery module that does not require disassembly according to claim 1, characterized in that: The structural component (3) is made of a rigid material.

3. The flexible thin-film sensor mounting device for a battery module that does not require disassembly according to claim 1, characterized in that: The depth of the groove (31) is greater than the thickness of the tightening band (2); the cross-section of the groove (31) is a rectangular groove or a trapezoidal groove.

4. The flexible thin-film sensor mounting device for a battery module that does not require disassembly according to claim 1, characterized in that: The closed side of the groove (31) has a planar structure, and the closed side of the groove (31) is in close contact with the flexible thin film sensor (4).

5. The flexible thin-film sensor mounting device for a battery module that does not require disassembly according to claim 1, characterized in that: The tightening band (2) is a steel cable tie.

6. The flexible thin-film sensor mounting device for a battery module that does not require disassembly according to claim 1, characterized in that: The battery module (1) includes two limiting frames (12), which are symmetrically distributed at both ends of the battery module (1); the battery cells (11) are clamped between the two limiting frames (12).

7. The flexible thin-film sensor mounting device for a battery module that does not require disassembly according to claim 6, characterized in that: The outer surface of the limiting frame (12) is provided with a limiting groove (121), and the tightening band (2) is embedded in the limiting groove (121).

8. The flexible thin-film sensor mounting device for a battery module that does not require disassembly according to claim 6, characterized in that: The limiting frame (12) is provided with limiting edges (122) around its perimeter, and the battery cell (11) is disposed in the groove surrounded by the limiting edges (122).

9. The flexible thin-film sensor mounting device for a battery module that does not require disassembly according to claim 1, characterized in that: A silicone pad (5) is provided between the closed side of the groove (31) and the surface of the battery cell (11), and the flexible thin film sensor (4) contacts the surface of the battery cell (11) through the silicone pad (5).

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