Bus Bar Temperature Sensing in Battery Modules With Embedded FPC Sensor
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Solution Overview
Problem
Existing rechargeable battery modules face challenges in accurately sensing the temperature of bus bars due to limited space, making it difficult to fit commercialized temperature sensors effectively.
Innovation Solution
A rechargeable battery module design that incorporates a temperature sensor mounted on a flexible printed circuit (FPC) inserted into a groove of the bus bar, combined with a heat transfer material and member to efficiently detect temperature, allowing for precise temperature sensing within narrow spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a commercialized temperature sensor is attached to the bus bar using existing structures, then temperature sensing accuracy is improved, but the available space is excessively consumed
Solution Approach 1:
The temperature sensor is nested within a groove formed on the bus bar surface. The groove has a bottom surface and side surfaces that surround the temperature sensor, allowing the sensor to be positioned in a recessed area rather than on the external surface. This nesting approach enables accurate temperature sensing while minimizing the external space occupied by the sensor assembly.
Solution Approach 2:
Instead of attaching the temperature sensor to the external surface of the bus bar (2D surface mounting), the sensor is positioned within a groove that extends into the bus bar thickness (utilizing the 3D volume). This dimensional transition from surface mounting to embedded positioning reduces the footprint on the bus bar surface while maintaining thermal contact.
2Ease of operation
If the available space above and below the bus bar is utilized, then temperature sensor attachment is enabled, but the narrow space constraint prevents fitting commercialized sensors
Solution Approach 1:
The groove structure nests the temperature sensor within the bus bar thickness, utilizing the available vertical space between the top and bottom surfaces of the bus bar. The groove depth and width are designed to accommodate the sensor while remaining within the narrow space constraints of the battery module assembly.
Solution Approach 2:
The groove is positioned at a specific location on the bus bar where there is sufficient local space. The local geometry of the groove (depth, width, orientation) is optimized to accommodate the temperature sensor while considering the narrow overall space available in the battery module. This localized structural modification enables sensor placement without requiring changes to the entire bus bar or surrounding assembly.
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 enables accurate temperature detection of bus bars within a limited deviation, even in narrow spaces, by utilizing a heat transfer path that minimizes additional space requirements and ensures effective heat transfer from the bus bar to the temperature sensor.
Implementation Method 1
a heat transfer material between a surface of the bus bar, on a side of the groove, and the temperature sensor and configured to transfer heat from the surface of the bus bar, on the side of the groove, to the temperature sensor
Implementation Method 2
a heat transfer member attached to the second surface of the flexible printed circuit and configured to transfer heat from the bus bar to the temperature sensor
Data Source
AI summary
A rechargeable battery module is provided. The rechargeable battery module may include: a bus bar holder configured to cover a plurality of battery cells; a bus bar positioned in the bus bar holder, the bus bar configured to output a voltage of at least one of the battery cells, and the bus bar having a groove extending into the bus bar in a thickness direction; a flexible printed circuit attached to one of the first and second surfaces of the bus bar, the flexible printed circuit comprising a first surface and a second surface, and the flexible printed circuit being configured to send a signal indicating a temperature of the bus bar; a temperature sensor mounted on the first surface of the flexible printed circuit, inserted into the groove, and configured to detect the temperature of the bus bar; a heat transfer material between a surface of the bus bar, on a side of the groove, and the temperature sensor and configured to transfer heat from the surface of the bus bar, on the side of the groove, to the temperature sensor; and a heat transfer member attached to the second surface of the flexible printed circuit and configured to transfer heat from the bus bar to the temperature sensor.