Battery Temperature Sensor Insert with Load Distribution

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Solution Overview

Problem

Existing temperature detecting devices for high-voltage batteries in electric vehicles face challenges in accurately detecting battery cell temperatures due to insufficient attachment of thermistors and weakness in the bus bar cover structure, which can lead to inaccurate temperature readings and potential damage from foreign matter insertion.

Innovation Solution

A temperature detecting device with a base and insert configuration that includes a flexible portion and load distribution structures to guide and secure the thermistor unit, allowing for improved attachment and load distribution, preventing damage from foreign matter and enhancing temperature detection accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the thermistor is attached to the battery cell outer wall and pressed by the bus bar cover, then the thermistor is prevented from coming off, but the attachment working property and temperature detection accuracy are insufficient

Engineering Contradiction:

Improvethermistor attachment reliabilityVSAvoidattachment working property

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The bus bar cover is divided into a base and a separate insert. The insert includes a base portion with an accommodation space for the temperature detection unit and a grip portion for insertion. This segmentation allows the insert to be easily inserted into the base to secure the thermistor, significantly improving the attachment working property while maintaining reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insert acts as an intermediary component between the base and the temperature detection unit. It provides a structured mechanism with guide surfaces that facilitate proper positioning and secure attachment of the thermistor to the battery cell, improving both ease of operation and attachment reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the insert is simply inserted into the base, then the attachment process is simplified, but the strength at the periphery of the insertion hole is insufficient

Engineering Contradiction:

Improveattachment simplicityVSAvoidinsertion hole periphery strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

Load distribution portions are provided at the periphery of the insertion hole in the base. These localized structural features concentrate strength where needed without complicating the overall simple insertion process. The load distribution portions prevent crack propagation and enhance the structural integrity of the insertion hole periphery.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The load distribution portions are designed in advance to cushion and distribute mechanical loads that may occur during insertion or subsequent use. This preemptive design prevents stress concentration and potential failure at the insertion hole periphery, maintaining both simplicity and strength.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Device complexity

If the insert lacks guiding structures, then the device complexity is reduced, but the insertion precision and temperature detection accuracy are compromised

Engineering Contradiction:

Improveinsert structure complexityVSAvoidinsertion precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The insert features asymmetric guide surfaces with specific inclination angles on the base portion. These asymmetric guiding structures provide precise directional guidance during insertion without requiring complex mechanisms. The asymmetric design ensures accurate positioning of the temperature detection unit relative to the battery cell while keeping the overall structure simple.

Inventive Principle:

Principle #4Asymmetry

4Manufacturing precision

If the base portion accommodation space is tightly fitted, then the temperature detection unit positioning is improved, but the insertion difficulty increases

Engineering Contradiction:

Improvepositioning precisionVSAvoidinsertion ease

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The fit between the insert base portion and the base accommodation space is designed to be dynamic rather than statically tight. The grip portion provides leverage for insertion, while the base portion gradually engages with the accommodation space. This dynamic insertion process allows easy installation while achieving precise positioning once inserted.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10847821B2Temperature detecting device and insertion hole structure of base

Publication Date: 2020.11.24 HONDA MOTOR CO LTD

AI summary

A temperature detecting device is equipped with an insertion hole structure for guiding a case which is inserted from outside into a holder that covers an outer wall of a battery cell, to the outer wall of the battery cell. In this insertion structure, a plurality of load distribution portions, specifically a first structure and a second structure, are formed at the periphery of an opening of an insertion hole. The load is generated upon abutment on a foreign matter that is about to enter through the insertion hole toward the battery cell. The load distribution portions distribute and release a load to the periphery of the opening.