Battery Pack Thermistor Mounting Guide
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Solution Overview
Problem
Existing battery packs face challenges in accurately measuring temperature and preventing damage to thermistors, which are crucial for safety and efficiency, due to difficulties in mounting and positioning thermistors during manufacturing.
Innovation Solution
A battery pack design that incorporates a protective circuit module with a thermistor, featuring a mounting portion and first rib portion to guide and secure the thermistor's position, creating a separate space to prevent damage and ensure accurate temperature measurement, while also supporting bare cells to prevent movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the thermistor is mounted directly on the bare cell without a protective structure, then the temperature measurement is direct and accurate, but the thermistor is vulnerable to damage during assembly and operation
Solution Approach 1:
The patent introduces a mounting portion with a head portion that acts as an intermediary between the thermistor and the bare cell. The head portion makes direct contact with the bare cell to sense temperature, while the connection portion connects to the protective circuit module. This intermediary structure protects the thermistor from damage during assembly while maintaining accurate temperature measurement capability.
2Measurement precision
If the thermistor mounting position is not precisely guided, then the assembly process is simple, but the thermistor cannot be positioned accurately to measure the bare cell temperature
Solution Approach 1:
The mounting portion is integrated into the protective circuit module housing, creating a self-guiding structure. The head portion's geometry and positioning features automatically guide the thermistor into the correct position during assembly, eliminating the need for complex external positioning mechanisms while ensuring accurate alignment with the bare cell for temperature measurement.
3Reliability
If the thermistor is exposed without protection, then the structure is simple, but the thermistor can be damaged during assembly or operation
Solution Approach 1:
The patent merges the protective function with the mounting function by integrating the mounting portion into the protective circuit module housing. The head portion, connection portion, and insulation film work together as a unified structure that both mounts the thermistor and protects it from damage, eliminating the need for separate protective components while maintaining reliability.
4Reliability
If no insulation is provided for the thermistor connection portion, then the structure is simpler, but electrical short circuits may occur between the thermistor and bare cell
Solution Approach 1:
The patent uses an insulation film to wrap the connection portion of the thermistor. This thin film provides electrical insulation between the connection portion and the bare cell, preventing short circuits while maintaining a compact structure. The flexible film conforms to the connection portion's shape and provides reliable insulation without adding significant structural 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 facilitates easier manufacturing, ensures precise temperature measurement, and enhances safety by preventing thermistor damage and ensuring accurate temperature sensing, while maintaining the structural integrity of the battery pack.
Implementation Method 1
a head portion for sensing a temperature of the bare cell
Implementation Method 2
a protective circuit module having a thermistor... a connection portion for transmitting the temperature of the bare cell, sensed by the head portion, to the protective circuit module
Data Source
AI summary
A battery pack including a plurality of bare cells, a protective circuit module having a thermistor, and a case accommodating the bare cells and the protective circuit module therein is disclosed. The case may include a mounting portion having the thermistor mounted thereon and a first rib portion. The mounting portion may form a separate space between the mounting portion and the bare cells. The first rib portion may be positioned in the separate space. Accordingly, the thermistor may be guided to a particular position within the case by the first rib portion, thereby preventing damage to the thermistor.