Battery Pack Thermal Sensor Seating Unit Design
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Solution Overview
Problem
Existing battery packs face challenges in preventing damage to temperature sensors and ensuring their reliable operation, which is crucial for monitoring battery cell temperatures and preventing overheating-related accidents.
Innovation Solution
A battery pack design that includes a protection circuit module (PCM) and a thermal sensor, where the thermal sensor is securely positioned within a frame with a seating unit and hole configuration to prevent falling and is connected via cables, ensuring the sensor's reliability and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thermal sensor is loosely positioned without a dedicated seating structure, then the device complexity is reduced, but the thermal sensor may fall or be damaged, reducing reliability
Solution Approach 1:
The frame is segmented into a main body and a separate seating unit that is specifically designed to hold the thermal sensor. This segmentation allows the seating unit to be optimized for sensor retention while keeping the rest of the frame structure simple and manageable.
Solution Approach 2:
The seating unit acts as an intermediary component between the frame and the thermal sensor. It provides a dedicated interface that secures the sensor in place, preventing it from falling or being damaged while maintaining overall structural simplicity.
2Reliability
If the thermal sensor is securely fixed in a dedicated seating unit, then the thermal sensor reliability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The seating unit with its hole for the thermal sensor is pre-formed as an integrated part of the frame structure. This preliminary action ensures proper alignment and positioning is built into the mold or fabrication process, eliminating the need for complex post-assembly alignment operations.
3Measurement precision
If the thermal sensor is positioned close to the battery cell for accurate temperature monitoring, then the temperature measurement accuracy is improved, but the risk of thermal damage to the sensor increases
Solution Approach 1:
The thermal sensor is nested within the seating unit that is integrated into the frame structure. This nested arrangement allows the sensor to be positioned close to the battery cell for accurate temperature monitoring while the seating unit provides a protective enclosure that shields the sensor from direct thermal exposure and potential damage.
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 design effectively prevents thermal sensor damage and enhances its reliability, improving the battery pack's ability to monitor temperature accurately and prevent overheating, thus ensuring safer operation and easier manufacturing.
Implementation Method 1
a thermal sensor that is electrically connected to the PCM and measures a temperature of the first battery cell
Data Source
AI summary
Provided is a battery pack. The battery pack includes; a first battery cell and a second battery cell; a protection circuit module (PCM) that is located between the first and second battery cells and is electrically connected to the first and second battery cells; a thermal sensor that is electrically connected to the PCM and measures a temperature of the first battery cell; and a frame that accommodates the first battery cell, the second battery cell, and the PCM, wherein the frame includes a seating unit on which the PCM is seated, and the seating unit comprises a hole for inserting the thermal sensor to fix a position of the thermal sensor. Accordingly, damage to the thermal sensor is prevented and reliability of the thermal sensor is increased.