Battery Temperature Sensor Flexible Mounting
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Solution Overview
Problem
Current lithium battery systems face challenges in accurate thermal management due to temperature sensors being affected by ambient temperature gradients and requiring additional components, which complicates their design and assembly.
Innovation Solution
A battery system design that incorporates a platform with apertures and flexible members to securely position temperature sensors close to the cells, allowing for accurate temperature detection without the need for additional fasteners, using sensors like thermistors or thermocouples coupled to flexible diaphragms for movement while maintaining proximity to the cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are attached to battery modules using additional parts and clips, then the sensors can be positioned on the modules, but the device complexity increases and assembly becomes more difficult
Solution Approach 1:
The temperature sensor is integrated directly into the battery cell structure, merging the sensing function with the cell housing. This eliminates the need for separate mounting clips and parts, reducing assembly complexity while maintaining measurement precision through direct thermal contact with the cell interior.
Solution Approach 2:
A thermal coupling medium or direct thermal path is introduced as an intermediary between the sensor and the battery cell, allowing accurate temperature measurement without requiring complex mechanical attachment structures. The intermediary ensures efficient heat transfer from the cell to the sensor while simplifying the mounting mechanism.
2Ease of manufacture
If temperature sensors are exposed to ambient temperature gradients, then the sensors can be positioned on battery modules, but the measurement precision deteriorates
Solution Approach 1:
The sensor positioning is optimized to create a localized thermal measurement zone within the battery cell, away from ambient temperature gradients. By placing the sensor in direct contact with the cell interior or using a thermal coupling mechanism, the system measures the actual cell temperature rather than ambient conditions, improving precision while maintaining ease of installation.
Solution Approach 2:
The sensor design incorporates preliminary thermal isolation or shielding measures that prevent ambient temperature gradients from affecting the measurement. This anti-action approach blocks external thermal interference before it can reach the sensor, ensuring accurate readings without complicating the installation process.
3Reliability
If multiple components and clips are used to attach sensors to battery modules, then the sensors can be securely positioned, but the assembly time and manufacturing complexity increase
Solution Approach 1:
The sensor mounting function is merged with the battery cell housing or a single integrated component, eliminating the need for multiple separate clips and fasteners. This integration maintains secure sensor positioning through a unified structure while dramatically reducing assembly steps and improving manufacturing productivity.
Solution Approach 2:
The sensor attachment mechanism is designed to self-align or self-secure during assembly, requiring minimal manual intervention. The sensor may utilize elastic retention, snap-fit mechanisms, or thermal expansion properties to automatically secure itself in the correct position, ensuring reliable positioning while accelerating the assembly process.
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 configuration simplifies assembly, reduces component count, maintains sensor accuracy, and allows for effective thermal management by ensuring consistent sensor contact with cells, enhancing the reliability and efficiency of lithium battery systems.
Implementation Method 1
a sensor coupled to the flexible member and positioned proximate the cell. The sensor is configured to detect a temperature of the cell
Data Source
AI summary
A battery system includes a platform having an aperture formed therethrough, a flexible member having a generally planar configuration and extending across the aperture, wherein a portion of the flexible member is coextensive with the aperture, a cell provided adjacent the platform, and a sensor coupled to the flexible member and positioned proximate the cell. The sensor is configured to detect a temperature of the cell.