Battery Pack PCB Layout for Accurate Cell Temperature Sensing
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Solution Overview
Problem
Existing energy storage units face challenges in accurately monitoring the temperature of energy storage cells due to suboptimal thermal coupling between temperature sensors and cells, leading to potential short-circuits, deformation, and incorrect measurements.
Innovation Solution
The implementation of a measurement system with a further printed circuit board electromechanically connected to the first printed circuit board, where the temperature sensor is strategically positioned to achieve an optimal distance for enhanced thermal coupling while preventing direct contact and minimizing heat dissipation, using a thermally conductive material in recesses to enhance heat transfer and reduce errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the temperature sensor is placed in direct contact with the energy storage cell to improve thermal coupling, then temperature measurement accuracy is improved, but the risk of short-circuit and deformation increases
Solution Approach 1:
The patent introduces a further printed circuit board as an intermediary element between the temperature sensor and the energy storage cell. This mediator enables thermal coupling through controlled proximity while maintaining electrical isolation, thus preventing short-circuits. The board acts as a thermal conduit that transfers heat from the cell to the sensor without requiring direct physical contact between the sensor and cell terminals.
Solution Approach 2:
The patent transitions from direct one-to-one contact to a multi-dimensional arrangement where the temperature sensor is positioned on a separate printed circuit board in close proximity to the energy storage cell. This spatial reconfiguration allows thermal coupling through the air gap and surrounding structure while maintaining electrical safety margins, effectively using the third dimension (z-axis distance) to resolve the contradiction.
2Speed
If the distance between the temperature sensor and energy storage cell is reduced to improve thermal coupling, then temperature measurement speed is improved, but the risk of damage from vibrations and falls increases
Solution Approach 1:
The further printed circuit board serves as a protective intermediary that absorbs and distributes mechanical stresses from vibrations and impacts. By positioning the temperature sensor on this separate board rather than directly on the cell, the system gains mechanical isolation while maintaining thermal proximity, thus protecting the sensor from damage during use.
3Device complexity
If a single printed circuit board is used to simplify the structure, then device complexity is reduced, but thermal coupling optimization and electrical isolation become difficult to achieve simultaneously
Solution Approach 1:
The patent divides the printed circuit board system into two separate boards: a first board for electrical connections and a further board for housing the temperature sensor. This segmentation allows independent optimization of each board's function - the first board handles high-current electrical connections while the further board provides a stable platform for the sensitive temperature sensor with optimized thermal coupling to the energy storage cell.
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 configuration ensures precise temperature monitoring with reduced risk of short-circuits and deformation, providing accurate and fast responses to thermal changes while minimizing heat dissipation and manufacturing costs.
Implementation Method 1
at least one temperature sensor for sensing a temperature of the at least one energy storage cell... A particularly advantageous thermal coupling between the at least one temperature sensor and the at least one energy storage cell being measured is in this way possible
Data Source
AI summary
An energy storage unit for an electrical consumer includes at least one energy storage cell, a first printed circuit board for electrically contacting the at least one energy storage cell having a first and a second power supply contact of the energy storage unit. The first printed circuit board is arranged adjacent to the at least one energy storage cell and comprises at least one temperature sensor for sensing a temperature of the at least one energy storage cell. At least one further printed circuit board is electromechanically connected to the first printed circuit board and the at least one temperature sensor is arranged on the at least one further printed circuit board. The energy storage unit can be used with an electrical consumer such as a hand-held power tool with the energy storage unit designed as a removeable battery pack.