Busbar Holder Assembly for Fast Battery Temperature Sensor Mounting
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Solution Overview
Problem
Existing battery module manufacturing processes face challenges in efficiently integrating temperature sensors to monitor battery cell temperatures, leading to increased defect rates and manufacturing time.
Innovation Solution
A busbar holder assembly is designed to include a temperature sensor cover with a second fastening portion and an elastic member between the circuit board and the temperature sensor cover, allowing for secure fixation of the temperature sensor assembly to the busbar holder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensor assembly is integrated into battery module, then temperature monitoring capability is improved, but manufacturing complexity increases
Solution Approach 1:
The temperature sensor assembly is nested within the busbar holder structure. The receiving hole in the busbar holder accommodates the temperature sensor assembly, and the fastening portions integrate the sensor assembly into the existing holder structure without requiring separate mounting operations.
Solution Approach 2:
The temperature sensor assembly is merged with the busbar holder by integrating the fastening portions directly into the holder structure. The first fastening portion of the busbar holder connects with the second fastening portion of the temperature sensor cover, combining two functional components into a unified assembly.
2Ease of manufacture
If traditional temperature sensor integration method is used, then manufacturing process is simple, but defect rate increases and manufacturing time increases
Solution Approach 1:
The busbar holder is designed with pre-formed fastening portions (first and second fastening portions) that are prepared in advance during holder manufacturing. The receiving hole and fastening structures are created beforehand, allowing the temperature sensor assembly to be quickly and accurately installed without complex alignment procedures.
3Reliability
If temperature sensor assembly is securely fastened to busbar holder, then reliability of temperature monitoring is improved, but manufacturing time increases
Solution Approach 1:
The fastening mechanism is segmented into two distinct portions: the first fastening portion integrated into the busbar holder and the second fastening portion on the temperature sensor cover. This segmentation allows for modular assembly where each portion can be independently prepared and then quickly connected, ensuring secure fastening while maintaining manufacturing efficiency.
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 proposed solution reduces defect rates and manufacturing time by providing a reliable and efficient method for integrating temperature sensors into battery modules, thereby enhancing the monitoring of battery cell temperatures.
Implementation Method 1
an elastic member between the circuit board and the temperature sensor cover
Implementation Method 2
The temperature sensor cover may be fixed to an upper surface of the elastic member using adhesive
Data Source
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AI summary
A battery module includes battery cells, busbars electrically connecting the battery cells, a circuit board including a temperature sensor assembly, and electrically connected to the busbars, and a busbar holder for supporting the busbars, defining a receiving hole for receiving the temperature sensor assembly, and including a first fastening portion (30) adjacent to the receiving hole, wherein the temperature sensor assembly includes a temperature sensor (544) configured to measure a temperature of at least one of the battery cells, a temperature sensor cover (546) including a second fastening portion (610) configured to be fastened to the first fastening portion, and an elastic member (542) between the circuit board and the temperature sensor cover.