Battery Connection Module With Busbar-Coupled Temperature Sensing
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Solution Overview
Problem
Existing battery connection modules suffer from inaccurate temperature collection due to temperature sensors being distanced from heat sources, and structural weaknesses in the upper case leading to potential damage and warping.
Innovation Solution
A battery connection module design with temperature sensors directly adjacent to heat-generating busbars via thermally conductive metal bridging pieces and a robust upper cover latching mechanism without broken holes to enhance temperature accuracy and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensing members are provided on the flexible circuit board at a distance from batteries and busbars, then the structural integrity of the circuit board is maintained, but the accuracy of temperature collection is affected
Solution Approach 1:
A metal bridging piece is introduced as an intermediary component between the temperature sensing member and the busbar. This metal piece serves dual functions: it thermally couples the temperature sensor to the heat-generating busbar for accurate temperature measurement, while also providing mechanical support and electrical connection, thus resolving the contradiction between measurement accuracy and structural integrity
Solution Approach 2:
The patent combines multiple functions into the metal bridging piece: thermal conduction (heat transfer from busbar to sensor), electrical conduction (electrical connection), and mechanical support (structural reinforcement). This merging eliminates the need for separate components, improving temperature collection accuracy without significantly increasing overall device complexity
2Ease of operation
If latching pieces with apertures and slits are provided to the upper case, then the latching mechanism can be assembled, but the constructional strength of the upper case is destroyed leading to damage and warping
Solution Approach 1:
The latching mechanism is segmented into separate components: the upper case remains intact without apertures or slits, while the latching pieces are provided as separate elements that can be assembled into the upper case. This segmentation allows the latching function to be achieved without compromising the constructional strength and integrity of the upper case structure
Solution Approach 2:
The latching pieces are pre-formed with the necessary features for engagement, allowing them to be inserted into the upper case without requiring apertures or slits to be created in the upper case itself. This preliminary preparation of latching components enables easy assembly while preserving the strength of the upper case structure
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
Improves temperature collection accuracy and response time while preventing structural damage to the upper cover.
Implementation Method 1
the first metal bridging piece comprises a first end and a second end, the first end is connected to the setting surface of the tip of the flexible supporting arm, the second end is connected to the first busbar
Data Source
AI summary
A battery connection module includes a carrying tray, a plurality of busbars, a flexible circuit board and at least one temperature sensing construction, the plurality of busbars are assembled on the carrying tray and are used to connect the plurality of batteries in series; the flexible circuit board is assembled on the carrying tray and includes a plurality of flexible supporting arms which extend from the flexible circuit board to connect the plurality of busbars, the temperature sensing construction includes a first flexible supporting arm, a first busbar, a temperature sensor and a first metal bridging piece, the first flexible supporting arm is one of the plurality of flexible supporting arms and the first busbar is one of the plurality of busbars, the first busbar has a depressed portion close to the flexible circuit board, a tip of the flexible supporting arm has a setting surface which is used to provide the temperature sensor thereon, the temperature sensor is directly positioned above the depressed portion, the first metal bridging piece includes a first end and a second end, the first end is connected to the setting surface of the tip of the flexible supporting arm, the second end is connected to the first busbar.