Battery Module Thermistor Mounting for Accurate Temperature Sensing
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Solution Overview
Problem
In battery modules, the temperature measurement accuracy is compromised due to unreliable connections between thermistors and batteries, especially under high current conditions and with adhesive fixation, which leads to significant deviations in temperature readings over time.
Innovation Solution
A battery module design featuring a positioning bracket with a first opening for electrode terminals, a circuit board with a thermistor mounted on a reinforcing plate, and a fixing cover plate that securely presses the circuit board to the battery top cover, enhancing thermal contact and connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the thermistor is placed on an electrical connecting piece to collect temperature, then the temperature can be collected, but under high current conditions the connecting piece generates excessive heat causing large deviation between measured and actual battery temperature
Solution Approach 1:
The patent introduces a dedicated temperature collecting component (thermal sensor) that acts as an intermediary between the battery and the measurement system. This component is specifically positioned to detect battery temperature without being affected by the heat generated in electrical connecting pieces during high current operation, thereby eliminating the measurement deviation caused by placing sensors on current-carrying components.
Solution Approach 2:
The patent separates the temperature collection function from the electrical connection function. Instead of using the electrical connecting piece for both current conduction and temperature sensing, the design divides these functions into distinct components: the electrical connecting piece handles current transmission while a separate thermal sensor dedicated to temperature measurement is positioned to collect temperature data directly from the battery, avoiding the thermal interference of high current paths.
2Ease of manufacture
If the thermistor is directly fixed to the battery by adhesive, then the connection is simple, but over time the adhesive deteriorates due to temperature and battery expansion causing loss of connecting reliability
Solution Approach 1:
The patent introduces a positioning bracket as an intermediary component between the thermal sensor and the battery. This bracket provides a stable mechanical mounting structure that is not affected by adhesive deterioration. The positioning bracket maintains consistent thermal contact pressure on the thermal sensor throughout the battery's operational life, eliminating the reliability issues associated with adhesive degradation from temperature cycling and expansion.
3Reliability
If a positioning bracket is used to fix the circuit board, then the connection reliability is improved, but the device complexity increases
Solution Approach 1:
The positioning bracket is designed to perform multiple functions simultaneously: it provides mechanical support for the circuit board, ensures stable thermal contact between the thermal sensor and the battery, and maintains proper positioning throughout operation. By consolidating these functions into a single component rather than using separate elements for each function, the design achieves high reliability without proportionally increasing complexity.
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 improves the accuracy of temperature collection by ensuring a stable and reliable connection between the thermistor and the battery, reducing temperature deviations and maintaining accurate readings even under expansion and high current conditions.
Implementation Method 1
a fixing cover plate, tightly pressing the second mounting portion of the circuit board in the up-and-down direction (Z) to fix the second mounting portion to the top cover of the one of the plurality of batteries
Implementation Method 2
The thermistor is fixedly disposed on the second mounting portion of the circuit board... the thermistor can accurately collect the temperature of the battery
Data Source
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AI summary
The present invention provides a battery module, comprising a plurality of batteries; a positioning bracket, a circuit board, a thermistor and a fixing cover plate. The positioning bracket is provided with a first opening. The circuit board has a second main body portion and a second mounting portion contained in the first opening and supported on the battery. The thermistor is directly disposed on the circuit board, the mounting between the two is simple, and sampling can be realized without switching, thereby improving the connecting reliability between the thermistor and the circuit board. Meanwhile, since the thermistor collects the temperature of the top cover of the battery, the temperature of the top cover of the battery is closer to the actual temperature of the battery, so that the deviation between the temperature collected by the thermistor and the actual temperature of the battery is reduced, thereby greatly improving the accuracy of temperature collection of the thermistor.