Elastic Retaining Element for Battery Temperature Sensor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery systems for electric and hybrid vehicles face issues with heat transfer between temperature sensors and cell surfaces due to positional tolerances and air gaps, leading to suboptimal measurement accuracy and mechanical stress.
Innovation Solution
A two-stage elastic holding element with a first step acting as an initial stop and a second step engaging only upon deformation, providing secure positioning and compensation for misalignments, combined with a cone or stepped design to enhance stiffness and reduce mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple elastic or compressible element is used to press the temperature sensor against the cell housing, then the mounting is simple and inexpensive, but air gaps may form due to misalignments or tolerance variations, deteriorating heat transfer
Solution Approach 1:
The elastic holding element is divided into two functional sections: a first section with a first step that provides initial positioning, and a second section with a second step that engages only after deformation. This segmentation allows the element to first accommodate misalignments through the first step, then achieve secure two-point contact through the second step, ensuring both ease of manufacture and reliable heat transfer without air gaps
Solution Approach 2:
The elastic holding element is designed to be deformable, transitioning from an initial state where only the first step is engaged to a deformed state where the second step engages with the temperature sensor. This dynamic behavior allows the element to adapt to positional tolerances and misalignments during installation, then provide rigid two-point contact for optimal heat transfer, resolving the contradiction between simple mounting and precise positioning
2Manufacturing precision
If the elastic holding element is made very stiff to securely hold the temperature sensor, then positioning accuracy improves, but the element cannot compensate for positional tolerances and misalignments
Solution Approach 1:
The elastic holding element utilizes controlled deformation to resolve the contradiction between stiffness and adaptability. In its initial state, the element remains relatively flexible to accommodate misalignments and positional tolerances. Upon installation, when the element is deformed, it engages the second step to provide rigid two-point contact for precise positioning. This dynamic transition from flexible to rigid behavior allows the element to both compensate for tolerances and ensure accurate positioning
Solution Approach 2:
The first step of the elastic holding element is designed to engage with the temperature sensor before the second step engages. This preliminary engagement allows the element to initially accommodate misalignments and positional variations, guiding the temperature sensor into proper alignment. Only after this preliminary positioning does the second step engage to provide secure two-point contact, ensuring both tolerance compensation and positioning accuracy
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
This configuration ensures improved heat transfer and secure attachment of the temperature sensor, compensating for positional tolerances and reducing mechanical stress, thereby enhancing measurement accuracy and reliability.
Implementation Method 1
an elastic holding element which is set up to attach the temperature sensor to the surface of the at least one cell press
Implementation Method 2
the second paragraph is effective only with sufficient deformation of the holding element as a stop for a second paragraph of the temperature sensor
Implementation Method 3
Tolerances in the vertical distance between the cell and the receiving device can also be well compensated for by the elastic properties of the holding element
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Battery system comprising a plurality of cells (1), a temperature sensor (3) configured to detect the temperature on a surface of at least one cell (1), an elastic retaining element (4) configured to press the temperature sensor (3) against the surface of the at least one cell (1) and supported on a receiving device (2), wherein the retaining element (4) has a first shoulder (4.1) and a second shoulder (4.2), wherein the first shoulder (4.1) acts as a stop for a first shoulder (3.1) of the temperature sensor (3), and wherein the second shoulder (4.2) acts as a stop for a second shoulder (3.2) of the temperature sensor (3) only when the retaining element (4) is deformed.