Busbar Sensor Assembly for Battery Thermal Diffusion Prediction

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Solution Overview

Problem

Existing power battery systems lack the ability to accurately predict the direction of thermal diffusion and breakdown points during thermal runaway, hindering effective failure cause analysis and increasing rescue risks.

Innovation Solution

Incorporating temperature sensors and air pressure sensors into busbar assemblies within the battery module, along with insulating layers, to detect temperature and pressure changes, and a controller to analyze these signals for predicting thermal diffusion and breakdown points.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If temperature sensors are integrated into busbar assemblies to detect temperature at multiple positions, then the ability to predict thermal diffusion direction and breakdown points is improved, but the device complexity increases

Engineering Contradiction:

Improvethermal diffusion prediction accuracyVSAvoidbusbar assembly structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The temperature sensor is integrated directly into the busbar assembly structure, merging the sensing function with the existing electrical connection component. This eliminates the need for separate sensor housings and mounting structures, thereby improving measurement precision while minimizing the increase in device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The busbar assembly is designed to serve multiple functions: electrical connection, structural support, and temperature sensing. By making the busbar assembly multi-functional, the patent avoids adding separate dedicated temperature monitoring structures, thus improving thermal monitoring capability without proportionally increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Object-affected harmful factors

If an inner heat shield insulating layer is arranged between the busbar and flexible circuit board, then the protection of components from high temperature is improved, but the device complexity increases

Engineering Contradiction:

Improvehigh temperature effect on componentsVSAvoidbusbar assembly structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

An inner heat shield insulating layer is introduced as an intermediary element between the busbar and the flexible circuit board. This insulating layer acts as a thermal barrier that protects sensitive components from high temperatures while maintaining the electrical connection function, thereby reducing the harmful thermal effects without significantly complicating the overall structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The busbar assembly is segmented into distinct functional layers: the conductive busbar, the insulating heat shield layer, and the flexible circuit board. This segmentation allows each layer to perform its specific function optimally while keeping the overall structure organized and manageable, reducing the negative impact of added complexity.

Inventive Principle:

Principle #1Segmentation

3Reliability

If an outer insulating layer is configured to wrap the busbar and flexible circuit board, then the prevention of electrical arcs and short circuits is improved, but the device complexity increases

Engineering Contradiction:

Improveelectrical insulation reliabilityVSAvoidbusbar assembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

An outer insulating layer is designed to wrap around the busbar and flexible circuit board assembly. This flexible insulating shell provides comprehensive electrical insulation protection, preventing electrical arcs and short circuits between adjacent battery cells, while its wrap-around design adapts to the existing structure without requiring complex additional components.

Inventive Principle:

Principle #30Flexible shells and thin films

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

Enables precise prediction of thermal diffusion and breakdown points, enhancing safety by improving rescue efficiency and facilitating failure cause analysis.

Implementation Method 1

a flexible circuit board, which is integrated with a temperature sensor and outputs a temperature signal detected by the temperature sensor

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250337125A1Power Battery System for a Vehicle and Thermal Assessment Method

Publication Date: 2025.10.30 MERCEDES BENZ GROUP AG

AI summary

Please substitute the new Abstract submitted herewith for the original Abstract:A power battery system of a vehicle includes a battery module which at least has a plurality of battery cells and a plurality of busbar assemblies. The busbar assemblies are configured to connect adjacent battery cells. The busbar assembly has a busbar which is connected to the battery cells, a flexible circuit board which is integrated with a temperature sensor and outputs a temperature signal, an inner heat shield insulating layer which is disposed at least between the busbar and the flexible circuit board, an outer insulating layer which is configured to wrap the busbar and the flexible circuit board, and a controller which is configured to receive a temperature signal detected by the temperature sensor of each of the busbar assemblies and to predict a direction of thermal diffusion and/or a breakdown point of the battery module according to the temperature signals.