Battery Pack Strain Sensor Layout for Small Expansion Detection
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Solution Overview
Problem
Conventional devices struggle to accurately detect the small strain caused by battery expansion in battery packs, leading to difficulties in monitoring battery health effectively.
Innovation Solution
A sensor module comprising a metal strain generating body with a Cr mixed phase film strain gauge, strategically positioned on the housing of the battery pack to detect deformation with high sensitivity, utilizing adhesive regions and a non-adhesive space to enhance strain detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a strain gauge is used to detect battery expansion, then the battery state can be monitored, but the detection accuracy is insufficient due to small strain magnitude
Solution Approach 1:
The patent changes the physical parameters of the strain gauge by using a Cr mixed phase film with specific crystal structures (Cr, Cr2N, CrN) and controlling its thickness (50-200nm) to enhance the gauge factor and detection sensitivity for small strain measurements
Solution Approach 2:
The patent employs a composite film structure consisting of multiple layers including Cr mixed phase film, CrN film, and Cr2O3 film, where each layer contributes different properties to achieve high detection accuracy while maintaining stability
2Reliability
If adhesive regions are added to secure the strain gauge, then the detection stability is improved, but the strain detection accuracy may be reduced due to adhesive interference
Solution Approach 1:
The patent divides the substrate into distinct adhesive regions and non-adhesive regions, where adhesive regions provide secure mounting and non-adhesive regions ensure accurate strain transmission to the gauge, eliminating the trade-off between stability and accuracy
Solution Approach 2:
The patent applies different properties to different regions: adhesive regions have high bonding strength to ensure stability, while non-adhesive regions have optimal mechanical properties for strain transmission, achieving both reliability and precision simultaneously
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 sensor module effectively detects battery expansion with increased sensitivity, allowing for accurate monitoring of battery state and deformation, thereby improving the detection of battery health and preventing issues like liquid leakage.
Implementation Method 1
a strain gauge including a Cr mixed phase film as a resistor, the strain gauge being provided on one side of the strain generating body
Implementation Method 2
a strain gauge including a Cr mixed phase film as a resistor
Implementation Method 3
on another side of the strain generating body, a plurality of adhesive regions separated from each other and adhered to the housing are defined
Data Source
AI summary
A sensor module includes a strain generating body that is made of metal, the strain generating body being adhered to an outer surface of a housing configured to house a battery; and a strain gauge including a Cr mixed phase film as a resistor, the strain gauge being provided on one side of the strain generating body, wherein on another side of the strain generating body, a plurality of adhesive regions separated from each other and adhered to the housing are defined, and the strain gauge is arranged on the one side of the strain generating body in a region that is not opposite to the adhesive regions.