Battery Module Temperature Sensor Housing for High-Heat Reliability
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Solution Overview
Problem
Existing temperature sensors in lithium-ion battery modules are susceptible to high temperatures, leading to potential failure or slow response times, which poses a risk to the battery's operational safety and efficiency.
Innovation Solution
A temperature sensor with a housing made from a polymer composition that includes a thermotropic liquid crystalline polymer, offering high flow properties, good heat resistance, and high thermal conductivity to effectively manage temperature within the battery module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional temperature sensors are used in lithium-ion battery modules, then they can detect temperature to some extent, but they are susceptible to high temperatures causing failure or slow response time
Solution Approach 1:
The patent employs a composite housing structure made from polyether ether ketone (PEEK) material combined with thermal paste and heat dissipation fins. This composite material approach creates a housing that can withstand high temperatures while efficiently conducting heat away from the temperature sensor, thereby improving sensor reliability in high-temperature battery environments without causing failure or slow response.
2Measurement precision
If temperature sensors are placed in direct contact with battery cells for accurate measurement, then measurement precision improves, but the sensor is exposed to higher temperatures increasing failure risk
Solution Approach 1:
The patent introduces thermal paste as an intermediary substance between the temperature sensor and the battery cell surface. This thermal paste maintains intimate thermal contact for accurate temperature measurement while being contained within the protective PEEK housing, thus achieving precise measurement without directly exposing the sensor to extreme thermal conditions that would cause failure.
Solution Approach 2:
The PEEK housing material is selected for its stable thermal expansion properties that allow it to maintain structural integrity and sealing effectiveness across the operating temperature range. This ensures the sensor remains protected while still achieving accurate thermal contact with the battery cell through controlled expansion and contraction cycles.
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 proposed temperature sensor provides enhanced reliability and accuracy by maintaining functionality even at high temperatures, ensuring the safety and extended operational range of electric vehicles equipped with lithium-ion batteries.
Implementation Method 1
a housing that receives a temperature measuring element. The housing includes a polymer composition comprising a polymer matrix that includes a thermotropic liquid crystalline polymer
Implementation Method 2
The polymer composition exhibits a melt viscosity of about 300 Pa−s or less and a deflection temperature under load of about 170° C. or more
Data Source
AI summary
A temperature sensor comprising a housing that receives a temperature measuring element is provided. The housing includes a polymer composition comprising a polymer matrix that includes a thermotropic liquid crystalline polymer. The polymer composition exhibits a melt viscosity of about 150 Pa−s or less and a deflection temperature under load of about 170° C. or more.