Adjustable Temperature Sensor Support for Battery Pack Thermal Monitoring
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Solution Overview
Problem
Existing battery packs face challenges in accurately measuring the temperature of battery cells due to inconsistent contact between temperature sensors and cells of varying thicknesses, which can compromise safety and reliability.
Innovation Solution
A battery pack design featuring a case with a temperature sensor support portion that can be adjusted in height to match the thickness of the polymer cell, ensuring reliable contact and accurate temperature sensing, and including a protective circuit module (PCM) connected to the battery cells and temperature sensor via a cable with a guide portion for secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a fixed-height temperature sensor support portion is used in the case, then the manufacturing process is simple, but the temperature sensor cannot reliably contact battery cells of varying thicknesses, compromising measurement precision
Solution Approach 1:
The temperature sensor support portion is designed with adjustable height capability, allowing it to adapt to different battery cell thicknesses. This dynamic adjustment ensures reliable contact between the temperature sensor and the battery cell surface regardless of cell thickness variations, thereby maintaining measurement precision while accommodating design flexibility.
Solution Approach 2:
The height of the temperature sensor support portion can be changed according to the thickness of the battery cell. By adjusting this geometric parameter, the system achieves reliable temperature sensor contact across varying cell thicknesses, resolving the contradiction between measurement accuracy and structural simplicity.
2Reliability
If the temperature sensor support portion is adjusted to match different battery cell thicknesses, then temperature sensing reliability improves, but the manufacturing process becomes more complex
Solution Approach 1:
The adjustable height feature is implemented specifically at the temperature sensor support portion, which is a localized component within the case. This targeted approach improves temperature sensing reliability at the critical measurement point without requiring the entire case structure to be redesigned, thereby limiting the increase in manufacturing complexity to a specific component.
3Measurement precision
If the temperature sensor is positioned closer to the battery cell surface, then temperature measurement accuracy improves, but the risk of thermal damage to the sensor increases
Solution Approach 1:
The temperature sensor support portion acts as an intermediary structure between the temperature sensor and the battery cell surface. It provides a controlled contact interface that ensures adequate thermal contact for accurate measurement while maintaining a protective distance or thermal barrier that prevents direct exposure of the sensor to extreme temperatures that could cause 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
This design enhances the reliability of temperature measurement, improves safety by ensuring precise temperature sensing across battery cells of different thicknesses, and allows for improved contact between the temperature sensor and the battery cell, thereby enhancing the overall safety and performance of the battery pack.
Implementation Method 1
a temperature sensor connected to the PCM to measure a temperature of at least one of the plurality of battery cells
Data Source
AI summary
A battery pack includes a plurality of battery cells, a protective circuit module (PCM), a temperature sensor and a case. Each battery cell has a terrace portion sealed so that an electrode tab of an electrode assembly is extracted to an outside. The PCM is electrically connected to the plurality of battery cells. The temperature sensor is connected to the PCM to measure a temperature of the battery cells. The case accommodates the plurality of battery cells, the PCM and the temperature sensor. The case includes a mounting portion on which the PCM is mounted, and a temperature sensor support portion protruded to be spaced apart from the mounting portion at a predetermined height is formed in one area of the mounting portion.