Temperature Sensor Attachment Structure for Battery Unit Cells
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Solution Overview
Problem
Existing attachment structures for temperature sensors in battery packs face challenges with size and cost due to large resin spring portions that cannot relax stress without increasing size, and complex assembly processes with numerous components.
Innovation Solution
An attachment structure using a flexible thin plate-shaped cable with a chip-shaped temperature measuring element and a metal leaf spring with legs surrounding the element, where the measuring element is sheathed with a moisture-proof material, reducing size and cost while allowing for space-saving attachment to a unit cell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a resin spring portion is used in the attachment structure, then the structure can provide elastic deformation capability, but the spring length must be increased to relax stress, resulting in increased size
Solution Approach 1:
The patent changes the material parameter from resin to metal for the leaf spring, which fundamentally alters the stress-relaxation characteristics. Metal materials provide higher elastic modulus and better stress relaxation capability, allowing the spring to be shorter while maintaining the same stress relaxation function. This parameter change directly resolves the contradiction between stress relaxation capability and spring length.
Solution Approach 2:
The patent employs a composite structure where the metal leaf spring works in conjunction with the resin holder and temperature sensor assembly. The metal spring provides the elastic deformation and stress relaxation function, while the resin components provide structural support and positioning. This composite approach allows optimization of each material's properties, enabling shorter spring length while maintaining overall functionality.
2Reliability
If multiple components are used in the attachment structure, then the structure can achieve stable temperature detection, but the number of components increases, making assembly complicated and increasing cost
Solution Approach 1:
The patent merges the spring function and holder function into an integrated assembly. The metal leaf spring is designed to directly support and position the temperature sensor, eliminating the need for separate resin springs and complex holding mechanisms. This merging reduces the component count while maintaining stable temperature detection through the rigid metal spring's precise positioning capability.
Solution Approach 2:
The metal leaf spring serves multiple functions simultaneously: it provides elastic deformation for contact pressure, acts as a structural support for the temperature sensor, and enables stable thermal contact with the battery surface. This multi-functionality reduces the overall component count while maintaining detection stability, as one component performs what previously required multiple separate parts.
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 solution reduces the size and cost of the temperature sensor, simplifies assembly, and enhances temperature measurement performance by using a flexible printed wiring board and metal leaf spring, allowing for efficient and compact integration with the unit cell.
Implementation Method 1
a metal leaf spring that is placed around the conductor exposed portion of the flexible thin plate-shaped cable and has a plurality of legs surrounding the temperature measuring element, and an elastic piece configured to energize the plurality of legs toward the unit cell
Implementation Method 2
the temperature measuring element is sheathed with a moisture-proof material between the plurality of legs of the metal leaf spring
Implementation Method 3
a chip-shaped temperature measuring element that is incorporated on a conductor exposed portion of the flexible thin plate-shaped cable and detects the temperature of the unit cell
Data Source
AI summary
An attachment structure for a temperature sensor that is attached to a flexible thin plate-shaped cable and detects the temperature of a unit cell of a battery pack having a plurality of unit cells connected with each other includes: the flexible thin plate-shaped cable; a chip-shaped temperature measuring element that is incorporated on a conductor exposed portion of the flexible thin plate-shaped cable and detects the temperature of the unit cell; and a metal leaf spring that is placed around the conductor exposed portion of the flexible thin plate-shaped cable and has a plurality of legs surrounding the temperature measuring element, and an elastic piece configured to energize the plurality of legs toward the unit cell. The temperature measuring element is sheathed with a moisture-proof material between the plurality of legs of the metal leaf spring.