Battery Pack Top Cover Temperature Sensor Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-power battery packs using non-aqueous electrolytes face challenges in accurately measuring and managing temperature across multiple cells, which can lead to reduced lifespan and performance due to heat generation during electrochemical reactions.
Innovation Solution
A battery pack design incorporating a temperature measuring member with a main body and wire portion made of thermal conductive materials, embedded sensors, and a controller to collect and manage temperature data, integrated into the top cover to ensure precise heat measurement and monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery cells are connected in series to form a high-power battery pack, then the energy density and power output are improved, but the temperature management complexity and heat measurement accuracy deteriorate
Solution Approach 1:
The battery pack is divided into multiple battery cell groups, with temperature measuring members independently installed for each group. This segmentation allows separate temperature monitoring for each cell group, simplifying the overall temperature management system while maintaining effective monitoring across the entire high-power battery pack.
Solution Approach 2:
A temperature measuring member consisting of a main body portion and a wire portion is introduced as an intermediary between the battery cells and the external monitoring system. The main body portion contacts the battery cell to detect temperature, while the wire portion transmits the temperature signal externally, enabling accurate temperature measurement without complex direct integration.
2Measurement precision
If temperature sensors are integrated into each battery cell, then the temperature measurement precision is improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The temperature measuring member is extracted as a separate component with two distinct parts: a main body portion that contacts the battery cell for temperature detection, and a wire portion that extends outward for signal transmission. This extraction simplifies the integration process compared to embedding sensors directly within each battery cell structure.
Solution Approach 2:
The temperature measuring member serves multiple functions: the main body portion acts as a temperature sensor in contact with the battery cell, while the wire portion serves as a signal transmission conduit. This multi-functional design reduces the need for separate components, simplifying the overall device complexity while maintaining measurement precision.
3Measurement precision
If a temperature measuring member with thermal conductive materials is used, then the heat measurement accuracy is improved, but the manufacturing complexity increases
Solution Approach 1:
The main body portion of the temperature measuring member is constructed using composite materials including at least one of a thermally conductive plastic, rubber, or silicon with elasticity. These composite materials provide both thermal conductivity for accurate heat measurement and elasticity for flexible installation, balancing manufacturing feasibility with measurement accuracy.
Solution Approach 2:
The material composition of the main body portion is optimized by selecting from thermally conductive plastics, rubbers, or elastic silicons. By changing the material parameters (thermal conductivity, elasticity), the system achieves accurate heat measurement while maintaining ease of manufacture through selection from established material families with known processing characteristics.
4Measurement precision
If the top cover includes an opening for the temperature measuring member, then the temperature monitoring capability is improved, but the structural integrity and sealing performance deteriorate
Solution Approach 1:
The temperature measuring member is routed through the thickness dimension of the top cover rather than creating lateral openings. The main body portion is positioned on one surface of the top cover while the wire portion exits through an opening on the opposite surface, utilizing the third dimension to minimize impact on the top cover's planar structural integrity.
Solution Approach 2:
The main body portion of the temperature measuring member is made from elastic materials such as rubber or silicon with elasticity. This flexibility allows the measuring member to pass through the top cover opening while maintaining a tight seal, preventing structural compromise and preserving the enclosure's integrity and sealing performance.
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 allows for accurate temperature measurement and management, enhancing the battery pack's performance and lifespan by preventing overheating and simplifying the assembly process through integrated temperature monitoring.
Implementation Method 1
a thermal conducting member between a bottom surface of the main body portion and the at least one of the battery cells
Implementation Method 2
a sensor, which sensor is built into the main body portion and measures a temperature of at least one of the battery cells
Data Source
AI summary
A battery pack includes a plurality of battery cells arranged along one direction, a top cover covering the plurality of battery cells and the top cover includes an opening in at least one portion thereof, and a temperature measuring member including a main body portion mounted in the opening and a wire portion accommodating a wire connected to a sensor. The sensor is built into the main body portion and measures a temperature of at least one of the battery cells.