Integrated Battery Sensing Module for Faster Heat and Voltage Pickup
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Solution Overview
Problem
Current battery module temperature and voltage acquisition systems lack standardization, leading to increased material variety, production costs, and low efficiency due to complex assembly processes and inefficient heat conduction paths, which hinder quick response to abnormal temperatures.
Innovation Solution
A temperature and voltage acquisition integrated module with a substrate of thermal and electrical conductivity, insulated temperature acquisition components, and voltage acquisition pads, optimizing heat conduction and standardizing the assembly process across different battery module specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature sensor is welded to the first pad and then covered by the protective segment of the first acquisition sheet, then the temperature sensor is protected, but the temperature sensor is not integrated with the first acquisition sheet, requiring separate assembly steps and preventing standardization
Solution Approach 1:
The temperature sensor is integrated directly with the first acquisition sheet through welding, merging two previously separate components into one unified structure. This eliminates the need for separate assembly steps while maintaining protection functionality, thereby reducing device complexity without compromising reliability
Solution Approach 2:
The first acquisition sheet serves multiple functions: it acts as both a protective segment covering the temperature sensor and as an integrated mounting structure for the sensor itself. This multi-functionality reduces the number of separate components needed, enabling standardization across different battery module specifications
2Adaptability or versatility
If different specifications of temperature and voltage acquisition assembly are prepared for battery modules with different specifications, then the acquisition assembly can be adapted to different battery cell quantities and sizes, but the variety of materials increases and production line processes become more complex
Solution Approach 1:
A single standardized temperature and voltage acquisition assembly design is created that can be universally applied to battery modules with different specifications. The assembly's modular nature allows it to adapt to various battery cell quantities and sizes without requiring different material types or complex production processes, thereby maintaining adaptability while reducing device complexity
Solution Approach 2:
The acquisition assembly is divided into standardized modular components (temperature sensor, voltage sensor, acquisition sheet, protective segment) that can be consistently assembled across different battery module configurations. This segmentation enables universal applicability without increasing material variety or production complexity
3Reliability
If a large gap is kept between the NTC thermistor and the inner wall of the NTC encapsulating housing to prevent short circuit, then short circuit is avoided, but the heat conduction path length increases, reducing heat transmitting efficiency
Solution Approach 1:
An intermediary material or structure is introduced between the NTC thermistor and the encapsulating housing that provides both electrical insulation (preventing short circuit) and thermal conduction (maintaining heat transmission efficiency). This intermediary resolves the contradiction by simultaneously satisfying both the reliability requirement for short circuit prevention and the energy efficiency requirement for effective heat conduction
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 solution achieves standardized temperature and voltage acquisition, reduces manufacturing complexity and material types, enhances heat conduction efficiency, and enables rapid detection of abnormal temperatures, improving overall product performance and safety.
Implementation Method 1
a substrate with thermal and electrical conductivity, connected to a busbar in the battery module
Implementation Method 2
a substrate with thermal and electrical conductivity, connected to a busbar in the battery module
Data Source
AI summary
A temperature and voltage acquisition integrated module for acquiring the temperature and voltage of a battery module includes a substrate with thermal and electrical conductivity for connecting to a busbar in the battery module; a temperature acquisition component, attached to the substrate, insulated and separated from the substrate by an insulating layer, provided with a temperature acquisition pad; a temperature sensor, welded to the temperature acquisition component; and a voltage acquisition pad, provided on the substrate and electrically connected to the substrate.