Battery Pack Temperature Sensor Mounting With Foam Pad Fixation
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Solution Overview
Problem
Existing battery packs face challenges in accurately sensing and stabilizing the position of temperature sensors, particularly when there is a large gap between the circuit board and the battery cell, which can lead to electrical interference and potential short circuits.
Innovation Solution
A battery pack design incorporating a temperature sensing structure with a foam pad portion containing a through portion for a film-type temperature sensor, allowing for easy position correction and fixation without welding, using adhesive tapes for secure attachment to both the circuit board and battery cell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is positioned between the circuit board and battery cell, then temperature sensing capability is improved, but position stability and accuracy deteriorate due to large gaps
Solution Approach 1:
The foam pad serves as an intermediary component between the circuit board and battery cell, providing a stable mounting structure for the temperature sensor. The foam pad fills the gap and provides adhesive surfaces for securing the sensor, thereby improving position stability while maintaining temperature sensing capability.
Solution Approach 2:
The temperature sensing structure is segmented into multiple components: the foam pad portion, the temperature sensor, and adhesive tapes. This segmentation allows each component to perform its specific function - the foam pad provides structural support and positioning, while the adhesive tapes secure the sensor in place, collectively resolving the position stability issue.
2Ease of manufacture
If adhesive tapes are used to fix the temperature sensor, then ease of manufacture is improved, but manufacturing precision deteriorates due to potential misalignment
Solution Approach 1:
The foam pad is pre-positioned between the circuit board and battery cell before the temperature sensor is installed. This preliminary action creates a stable base with adhesive surfaces already in place, making the subsequent sensor installation easier while maintaining proper alignment through the pre-established foam pad structure.
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 stability and accuracy of temperature sensing, prevents damage to the sensor, and ensures secure attachment without additional high-temperature processes, while accommodating varying gaps between the circuit board and battery cell.
Implementation Method 1
a first adhesion portion on a first penetrated surface portion of the foam pad portion, and the first adhesion portion attached to the circuit board... a second adhesion portion on a second penetrated surface portion of the foam pad portion, and the second adhesion portion attached to a surface of a plate of the battery cell
Data Source
AI summary
A battery pack includes at least one battery cell, a circuit board above the at least one battery cell, and a temperature sensing portion between a battery cell of the at least one battery cell and the circuit board, and the temperature sensing portion includes a foam pad portion including a through portion therein, and a temperature sensor arranged in the through portion.