Battery Temperature Sensor Wire Routing for Bend Load Protection
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Solution Overview
Problem
Existing temperature sensor devices for battery modules face issues with damage to the temperature sensor wire and element due to bending and tensile loads during routing, which can lead to breakage and damage to the inner elements.
Innovation Solution
The temperature sensor device incorporates a support body with a first and second structure for the temperature sensor wire, including locking portions and a joining portion to regulate twists and reduce curvature, ensuring the wire is routed in a manner that minimizes stress and curvature, and includes a voltage detection terminal for detecting battery cell voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the temperature sensor wire is routed directly from the temperature sensor element to the exterior, then the wiring is simple, but the wire is susceptible to breakage from bending and tensile loads
Solution Approach 1:
The patent introduces a support body as an intermediary component between the temperature sensor element and the exterior environment. This support body provides a protected routing path for the temperature sensor wire, allowing it to extend from the temperature sensor element through the support body to the exterior without being directly exposed to mechanical stresses. The support body acts as a mediator that shields the wire from bending and tensile loads while maintaining electrical connectivity.
Solution Approach 2:
The patent routes the temperature sensor wire through the thickness direction of the support body rather than along its surface. The wire extends from the temperature sensor element in the thickness direction of the support body and exits from the exterior surface opposite to where the element is mounted. This three-dimensional routing path through the support body structure reduces bending stresses compared to surface-level routing.
2Ease of manufacture
If the temperature sensor wire is allowed to move freely for easy installation, then the installation is simple, but the wire is susceptible to damage from tensile loads
Solution Approach 1:
The support body is pre-formed with a through-hole structure that guides the temperature sensor wire along a predetermined safe path. This preliminary preparation of the routing structure eliminates the need for complex wire management during installation while ensuring the wire is always protected from tensile loads. The installer simply needs to pass the wire through the pre-formed hole rather than creating a protective structure during installation.
3Measurement precision
If the temperature sensor element is directly exposed for temperature detection, then the detection is accurate, but the inner elements are damaged by external forces transmitted through the wire
Solution Approach 1:
The patent divides the temperature sensor assembly into distinct functional segments: the temperature sensor element mounted on one surface of the support body, the wire routing through the support body thickness, and the exterior connection point on the opposite surface. This segmentation isolates the fragile temperature sensor element from external mechanical forces while maintaining its temperature detection function. The support body structure creates a physical separation between the sensing element and potential damage sources.
Data Source
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AI summary
A temperature sensor device (30) includes a partial protector (300) covering at least a part of a battery cell (100), a support body (310) held on a holding structure (302) of the partial protector (300), a temperature sensor element (320) supported by the support body (310), and a temperature sensor wire (330) routed via a routing structure (304) of the partial protector (300) displaced in a predetermined direction from the holding structure (302) and electrically connected to the temperature sensor element (320). The support body (310) includes a drawn portion (314) drawn from the holding structure (302) and an attachment portion (316) displaced in the predetermined direction from the drawn portion (314) with the temperature sensor element (320) attached to the attachment portion (316).