Battery Temperature Sensor Mounting for Accurate Cell Sensing
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Solution Overview
Problem
Existing temperature sensor arrangements for energy storage devices, particularly in electric vehicles, are complex and costly to assemble, with direct heat transfer from cell connectors to control electronics leading to measurement deviations and potential damage from escaping gases during thermal runaway.
Innovation Solution
A temperature sensor configuration featuring a shaped housing element with mechanical connection means for easy attachment to a circuit board, including a snap connection and elastically deflectable spring arm for contact pressure, and a support structure integrating degassing and temperature control channels to simplify assembly and enhance safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If temperature sensors are directly integrated with cell connectors and control electronics, then assembly is simplified, but heat transfer from cell connectors to control electronics causes measurement deviations and potential damage
Solution Approach 1:
The patent divides the temperature monitoring system into separate functional modules: cell connectors for electrical connection, temperature sensors for measurement, and control electronics for processing. This segmentation prevents direct thermal coupling between heat-generating cell connectors and temperature-sensitive control electronics, eliminating measurement deviations while maintaining assembly simplicity through modular design.
Solution Approach 2:
The patent introduces thermal insulation materials and spatial buffers as intermediaries between cell connectors and control electronics. These intermediaries block harmful heat transfer paths, protecting the control electronics from thermal influence and ensuring accurate temperature measurements without complicating the assembly process.
2Speed
If control electronics are placed close to energy storage cells for monitoring, then response time is reduced, but exposure to escaping gases during thermal runaway increases
Solution Approach 1:
The patent segments the control system into spatially separated components: temperature sensors positioned near energy storage cells for immediate detection, and control electronics located at a safe distance. This segmentation enables fast response through localized sensing while protecting the electronics from harmful gases during thermal runaway events.
Solution Approach 2:
The patent introduces protective barriers and ventilation channels as intermediaries between the control electronics and potential gas escape paths. These intermediaries allow the control system to remain responsive to temperature changes while shielding the electronics from direct exposure to harmful gases during thermal runaway.
3Reliability
If multiple separate components are used for temperature sensing and electrical connection, then functional reliability is improved, but assembly complexity and cost increase
Solution Approach 1:
The patent employs segmentation to create distinct, standardized components for temperature sensing and electrical connection. Each component has a dedicated function, improving reliability through functional specialization. The standardized interfaces between segments simplify assembly procedures and reduce overall complexity despite the increased number of components.
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 reduces assembly effort, ensures accurate temperature measurement, and increases the reliability of energy storage devices by decoupling the circuit board from thermal and chemical influences, while providing controlled gas discharge during thermal runaway.
Implementation Method 1
a support structure, in particular a C-shaped support structure, which is open towards the cell connector and in which the sensor element is received in a receiving space, with the sensor element being pressed onto the cell connector by an elastic spring arm
Implementation Method 2
the sensor element being connected to the circuit board by a heat-conductive adhesive bond
Data Source
AI summary
A temperature sensor arrangement for a cell contacting system for contacting energy storage cells of an energy storage device, in particular an energy storage device for a vehicle, has a temperature sensor arrangement containing at least one sensor element. The at least one sensor element is connectable to a circuit board via connections. A shaped housing element is provided which is intended to support the sensor element. A mechanical connector is provided on the shaped housing element and serves to fix the shaped housing element to the circuit board.