Battery Module Sensor Tab Layout for Accurate Cell Temperature Sensing
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Solution Overview
Problem
Traditional battery module configurations face challenges with cumbersome and expensive integration of temperature sensing components, leading to inaccurate temperature measurements.
Innovation Solution
A battery module design that incorporates a bus bar carrier with a flex circuit, featuring a temperature sensor welding tab that extends through a window in the bus bar carrier to adhere to the surface of electrochemical cells, allowing for improved temperature detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional temperature sensing components are integrated into battery modules, then temperature monitoring capability is provided, but the integration becomes cumbersome and expensive
Solution Approach 1:
The temperature sensor is merged with the bus bar carrier to form an integrated assembly. The sensor becomes part of the bus bar carrier structure itself, eliminating separate mounting steps and reducing the number of components. This merging directly addresses the complexity issue by making the sensor integration inherent to the bus bar carrier manufacturing process.
Solution Approach 2:
The bus bar carrier is designed to serve multiple functions: it provides electrical connection through bus bars and simultaneously houses the temperature sensor. This multi-functionality reduces the need for separate dedicated sensor mounting structures, simplifying the overall integration process and reducing costs.
2Reliability
If traditional temperature sensing components are integrated into battery modules, then temperature monitoring capability is provided, but the measurement accuracy deteriorates
Solution Approach 1:
The temperature sensor is positioned at specific locations on the bus bar carrier that are thermally coupled to the battery cells. The sensor measures temperature at these critical thermal zones, ensuring accurate local temperature measurement that reflects the actual thermal conditions of the battery cells.
Solution Approach 2:
The bus bar carrier acts as an intermediary between the battery cells and the temperature sensor. It provides a stable mounting platform that maintains consistent thermal and mechanical contact with the cells, ensuring reliable temperature transmission to the sensor while protecting the sensor from direct exposure to harsh cell environments.
3Reliability
If temperature sensors are integrated into battery modules, then temperature monitoring is enabled, but manufacturing costs increase
Solution Approach 1:
The temperature sensor and bus bar carrier are manufactured as an integrated assembly, allowing simultaneous production of both components. This reduces the total number of parts, simplifies supply chain management, and enables economies of scale in manufacturing, directly lowering production costs.
Solution Approach 2:
The temperature sensor is pre-installed and secured to the bus bar carrier during its manufacturing process, before the carrier is installed in the battery module. This preliminary action eliminates the need for separate sensor installation steps during battery assembly, reducing labor costs and manufacturing complexity.
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 temperature measurement accuracy and reduces costs by simplifying the integration of temperature sensors within the battery module.
Implementation Method 1
a temperature sensor welding tab that extends through a window in the bus bar carrier to adhere to the surface of electrochemical cells
Data Source
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AI summary
A battery module includes electrochemical cells having an electrochemical cell with a terminal end. The battery module also includes a bus bar carrier configured to interface bus bars with terminals of the electrochemical cells and having a window. The battery module also includes a flex circuit disposed on the bus bar carrier, and a temperature sensor welding tab of the flex circuit. The temperature sensor welding tab includes a circuit engagement region coupled to the flex circuit, a welding region coupled to the terminal end of the first electrochemical cell, and a transverse region extending through the window of the bus bar carrier and between the circuit engagement region and the welding region.