Battery Module Sensor Welding Tab for Accurate Cell Temperature Sensing
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Solution Overview
Problem
Integrating traditional temperature sensing components in battery modules is cumbersome and expensive, leading to inaccurate temperature measurements.
Innovation Solution
A battery module design that includes a flex circuit with a temperature sensor welding tab extending through a window in a bus bar carrier, allowing direct coupling to electrochemical cell terminals for improved temperature detection using thermistors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional temperature sensing components are integrated in battery modules, then temperature monitoring is achieved, but the integration process becomes cumbersome and expensive
Solution Approach 1:
The temperature sensor is integrated directly into the bus bar carrier structure, merging the sensing function with the existing mechanical component. This eliminates separate mounting procedures and reduces the number of discrete parts, directly addressing the integration complexity issue while maintaining temperature measurement capability
Solution Approach 2:
The bus bar carrier is designed to serve multiple functions: electrical connection via bus bars, mechanical support, and temperature sensing through the integrated sensor. This multi-functionality reduces the need for additional components and simplifies the overall assembly process
2Measurement precision
If traditional temperature sensing components are used, then temperature monitoring is provided, but assembly costs increase
Solution Approach 1:
By combining the temperature sensor with the bus bar carrier into a single integrated assembly, the manufacturing process is simplified. The sensor and bus bars are pre-positioned and secured together, reducing assembly steps and labor costs while ensuring accurate temperature monitoring
Solution Approach 2:
The temperature sensor is pre-installed and secured to the bus bar carrier before final assembly with the battery module. This preliminary action ensures proper positioning and reduces the complexity of the final assembly process, lowering overall manufacturing costs
3Measurement precision
If temperature sensors are directly coupled to cell terminals, then temperature measurement accuracy improves, but the bus bar carrier structure must be modified
Solution Approach 1:
The bus bar carrier is redesigned to incorporate the temperature sensor as an integrated component, allowing it to serve both electrical connection and temperature sensing functions. This structural modification enables direct coupling to cell terminals while maintaining a unified component design
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
Enhances temperature measurement accuracy and reduces assembly costs by facilitating direct contact between thermistors and cell surfaces, improving overall module performance.
Implementation Method 1
a temperature sensor welding tab of the flex circuit... a welding region coupled to the terminal end of the first electrochemical cell... direct contact between thermistors and cell surfaces
Data Source
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.