Battery Pack PCB Cutout for Accurate Cell Temperature Sensing
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Solution Overview
Problem
Conventional temperature sensors in battery packs, due to being mounted on a printed circuit board (PCB) adjacent to battery cells, experience heat dissipation into the PCB, leading to inaccurate temperature readings that lag behind the actual battery cell temperature, potentially causing delayed shutdowns.
Innovation Solution
Incorporating a cutout in the PCB adjacent to the temperature sensor to prevent heat dissipation, ensuring the sensor more accurately tracks the battery cell temperature, and positioning the fuse away from the PCB to prevent melting during high current discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the temperature sensor is mounted on the PCB adjacent to the battery cells, then the sensor can monitor the battery cell temperature, but the PCB acts as a heat sink causing the sensor readings to lag behind the actual battery cell temperature
Solution Approach 1:
The patent extracts the temperature sensor from the PCB substrate by providing a cutout in the PCB that receives the temperature sensor, allowing the sensor to be positioned adjacent to the battery cell without the PCB acting as a heat sink. This separation eliminates the heat dissipation path through the PCB while maintaining close proximity to the battery cell for accurate temperature monitoring.
Solution Approach 2:
The patent introduces a thermal interface material or adhesive as an intermediary between the temperature sensor and the battery cell, facilitating direct thermal contact while isolating the sensor from the PCB's heat sink effect. This intermediary enables efficient heat transfer from the battery cell to the sensor without allowing heat to dissipate into the PCB.
2Volume of moving object
If the PCB is placed adjacent to the battery cells for compact design, then the battery pack size is reduced, but the PCB may melt during high current discharge
Solution Approach 1:
The patent extracts the fuse from the PCB substrate by providing a separate mounting location for the fuse away from the PCB. This allows the fuse to be positioned in a location that provides thermal protection for the PCB during high current discharge events, while maintaining a compact overall design.
Solution Approach 2:
The patent introduces a thermal barrier or insulating material as an intermediary between the PCB and the battery cells or high-current paths. This intermediary protects the PCB from excessive heat generation during high current discharge while allowing the PCB to remain adjacent to the battery cells for compact design.
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
The cutout on the PCB maintains the sensor's temperature closer to the battery cell's temperature, enabling timely shutdowns and preventing PCB melting, thus ensuring safety and accuracy in temperature monitoring.
Implementation Method 1
a temperature sensor for sensing the temperature of at least one of the battery cells
Implementation Method 2
a cutout in the printed circuit board positioned to retain heat in the temperature sensor such that the temperature of the temperature sensor more closely tracks the temperature of the plurality of battery cells
Implementation Method 3
Because the PCB upon which the temperature sensor is mounted can act like a heat sink, heat that is transferred from the battery cell to the temperature sensor may then be transferred to and dissipate throughout the PCB
Data Source
AI summary
The present invention is directed to a battery pack including improved fuse arrangement. The battery pack includes a plurality of battery cells, a battery cell holder holding the battery cells in a fixed position relative to each other, a printed circuit board attached to the battery cell holder and a busbar attached to the printed circuit board. The busbar may include a first leg extending away from the printed circuit board and a second leg extending away from the printed circuit board. The second leg is generally parallel to the first leg. The battery pack may further include a fuse. The fuse may include a first terminal connected to the first leg of the busbar and a second terminal connected to the second leg of the busbar such that the fuse is generally parallel to the printed circuit board.