Battery Module Temperature Sensor Mounting for Fast, Safe Top-Cover Sensing
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Solution Overview
Problem
Conventional temperature sensing assemblies in battery modules are prone to failure due to excessive pressure during mounting, leading to inaccurate temperature sensing and premature power limitations, which affect the performance and efficiency of battery modules, especially in high-power conditions.
Innovation Solution
A battery module structure that includes a temperature sensing assembly with a thermistor and thermal pad mounted on a wire harness board, pressed against a top cover, providing a short temperature transfer path and accurate temperature sensing, optimized by an elastic mounting portion and coaming to ensure stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional temperature sensing assembly is mounted in the battery module, then temperature sensing is provided, but the assembly receives excessive pressure during mounting which causes it to be crushed and fail
Solution Approach 1:
A mounting portion is introduced as an intermediary component between the temperature sensing assembly and the battery module. This mounting portion absorbs and distributes the mounting pressure, preventing excessive force from being transmitted directly to the temperature sensing assembly. The mounting portion acts as a buffer that protects the fragile sensing components while still enabling secure installation in the battery module structure.
Solution Approach 2:
The mounting portion is designed with cushioning characteristics to preemptively protect the temperature sensing assembly from crushing forces. By incorporating this protective structure in advance during the design phase, the system prepares for the harmful pressure effects before mounting occurs, ensuring the sensing assembly survives the installation process without being crushed.
2Speed
If the temperature sensing assembly is pressed closely against the top cover, then temperature response speed is improved, but the assembly may be damaged by excessive pressure
Solution Approach 1:
The mounting portion serves as a mediator that enables close contact between the temperature sensing assembly and the top cover while controlling the pressure applied. It allows the sensing assembly to be pressed sufficiently close to achieve fast temperature response, but distributes the force to prevent crushing damage to the sensitive components.
Solution Approach 2:
The mounting portion is designed to optimize the pressure parameter applied to the temperature sensing assembly. By carefully controlling the mounting pressure within an optimal range, the system achieves both fast temperature response (requiring close contact) and component protection (requiring limited force). The mounting portion transforms the pressure parameter from potentially harmful to beneficial.
3Ease of manufacture
If the connection piece has limited width and thickness, then manufacturing cost and space utilization are improved, but temperature sensing accuracy deteriorates due to large temperature difference between connection piece and battery interior
Solution Approach 1:
The mounting portion acts as a thermal intermediary that bridges the temperature sensing assembly and the battery interior. It provides a thermal conduction path that allows accurate temperature sensing of the battery interior despite the connection piece having limited dimensions. The mounting portion transfers heat efficiently from the battery interior to the sensing assembly, compensating for the limited thermal mass of the connection piece.
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 ensures fast and accurate temperature sensing, reducing premature power limitations and enhancing the efficiency and reliability of the battery module, optimizing performance in vehicles using the module.
Implementation Method 1
a thermal pad, where the thermistor is sandwiched between the mounting portion and the thermal pad, and the thermal pad abuts against the top cover
Data Source
AI summary
This application discloses a battery module, a battery pack, and a device, and relates to the field of battery technologies, to optimize a structure of the battery module. The battery module includes a battery, a wire harness board, a circuit board, and a temperature sensing assembly. The battery includes a top cover. The wire harness board is disposed on an outer side of the top of the top cover, and the wire harness board includes a body and a mounting portion disposed at the body. The circuit board is connected to the wire harness board. The temperature sensing assembly is mounted at the mounting portion, and pressed by the circuit board closely against the top cover. The battery module not only effectively implements temperature sensing at the top cover, but also prevents the temperature sensing assembly from being damaged due to excessive force applied by the circuit board.