Battery Module Temperature Sensor Mounting via Flexible PCB Spring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules face challenges in maintaining close contact between temperature sensitive elements and battery cells, especially under external impacts, leading to increased manufacturing costs due to complex mechanical arrangements.
Innovation Solution
A battery module design featuring a flexible printed circuit board with a spring element and a bracket, where the temperature sensitive element is positioned on a loop of the flexible board, ensuring close contact with the battery cell through a spring force, and the manufacturing process is simplified by using cost-effective materials and pre-mounting components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex mechanical arrangements are used to maintain close contact between temperature sensitive element and battery cell, then reliability is improved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent uses a flexible printed circuit board (FPC) as the mounting substrate for the temperature sensitive element. The FPC can elastically deform to accommodate relative movements between the battery cell and protective circuit module, maintaining continuous contact without requiring complex mechanical fixtures. This flexible film approach replaces rigid mechanical arrangements while ensuring reliable temperature sensing.
Solution Approach 2:
The patent introduces a spring element that applies elastic force to press the temperature sensitive element against the battery cell surface. This dynamic elastic contact mechanism allows the system to adapt to position changes and external impacts, maintaining reliable contact automatically without fixed mechanical constraints, thereby reducing structural complexity.
2Reliability
If complex mechanical arrangements are used to maintain close contact between temperature sensitive element and battery cell, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The flexible printed circuit board serves as both the electrical connection medium and the mounting structure for the temperature sensitive element. This integration eliminates the need for separate mechanical fixtures, reducing part count and assembly complexity, thereby lowering manufacturing costs while maintaining reliable contact.
Solution Approach 2:
The patent combines the electrical connection function and the mechanical support function into a single flexible printed circuit board structure. The FPC both connects the temperature sensitive element electrically and provides the elastic support needed to maintain contact with the battery cell, reducing the number of components and simplifying manufacturing.
3Manufacturing precision
If rigid structures are used to fix temperature sensitive element, then positioning precision is improved, but adaptability to relative movement decreases
Solution Approach 1:
The spring element provides elastic force that allows the temperature sensitive element to dynamically adjust its position in response to relative movements between the battery cell and protective circuit module. This elastic mechanism maintains precise contact pressure and positioning while accommodating position changes, combining precision with adaptability.
Solution Approach 2:
The flexible printed circuit board allows the temperature sensitive element to maintain its positioned relationship with the battery cell while the FPC itself can deform elastically. This flexible substrate provides both positioning stability during assembly and adaptability during operation when relative movements occur.
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 design ensures reliable temperature sensing even with relative movement between the battery cell and protective circuit module, reducing manufacturing complexity and costs while maintaining accurate positioning of the temperature sensitive element.
Implementation Method 1
A spring element is arranged within the loop of the flexible printed circuit board such that the temperature sensitive element is pushed towards the battery cell
Data Source
AI summary
A battery module includes: a battery cell; a protective circuit module electrically coupled to the battery cell; a temperature sensitive element at the battery cell; a flexible printed circuit board having first and second end portions and an inner portion extending between the first and second end portions; and a spring. The protective circuit module includes a rigid printed circuit board. The flexible printed circuit board is fixed to a surface of the rigid printed circuit board facing the battery cell by the first and second end portions such that the inner portion forms a loop, is electrically connected to the protective circuit module and to the temperature sensitive element, and is centrally positioned on the inner portion of the flexible printed circuit board. The spring is arranged within the loop of the flexible printed circuit board such that the temperature sensitive element is pushed towards the battery cell.