Elastomeric Thermistor Assembly for Battery Height Variation

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Solution Overview

Problem

In electrified vehicle battery assemblies, existing thermistor assemblies face challenges in reliably monitoring temperature conditions across battery cells with varying heights, due to inconsistent contact and potential disconnection issues.

Innovation Solution

A thermistor assembly featuring an elastomeric body with a thermistor housed inside, a protruding thermistor tip for contact with battery cells, and a housing that can accommodate cell height variations through compressible and flexible designs, ensuring consistent monitoring across battery cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a rigid thermistor assembly is used, then structural stability is improved, but adaptability to battery cells with varying heights deteriorates

Engineering Contradiction:

Improvestructural stabilityVSAvoidadaptability to cell height variations

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent employs an elastomeric body as a flexible housing to enclose the thermistor. This elastomeric material provides the necessary compliance to adapt to varying battery cell heights while maintaining structural integrity. The flexible nature of the elastomeric body allows the thermistor assembly to accommodate height variations without compromising structural stability.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The thermistor assembly incorporates movable or adjustable components that allow it to dynamically adapt to different cell heights. The assembly can transition between different positions or configurations to maintain optimal contact with battery cells of varying dimensions, thereby resolving the contradiction between structural stability and adaptability.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If the thermistor assembly is made flexible to accommodate height variations, then adaptability is improved, but measurement precision may deteriorate

Engineering Contradiction:

Improveaccommodation of height variationsVSAvoidtemperature monitoring precision

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The elastomeric body provides flexibility for adapting to height variations while the internal thermistor housing maintains rigidity to ensure precise temperature measurements. This dual-structure approach allows the outer shell to be compliant while the measurement-critical components remain stable and precise.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

Different parts of the thermistor assembly have different mechanical properties tailored to their specific functions. The elastomeric body is soft and compliant for adaptation, while the thermistor housing and mounting structures are rigid to ensure measurement precision. This local differentiation of material properties resolves the contradiction between flexibility and precision.

Inventive Principle:

Principle #3Local quality

3Reliability

If multiple parts are used to connect battery cells, then electrical connection reliability is improved, but device complexity increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The thermistor assembly integrates multiple functions into a single unified structure. The elastomeric body serves as both the housing and the adaptive mechanism, while the thermistor is directly mounted within this integrated structure. This consolidation reduces the number of separate parts needed while maintaining reliable electrical connection and temperature monitoring functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The thermistor assembly is designed to perform multiple functions simultaneously: it provides mechanical support, adapts to height variations, ensures electrical connection, and enables temperature monitoring. This multi-functional design reduces overall system complexity by eliminating the need for separate components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 thermistor assembly provides reliable temperature monitoring across battery cells with flexible accommodation of height variations, maintaining consistent contact and enhancing the monitoring of battery conditions.

Implementation Method 1

an elastomeric body and a thermistor housed at least partially inside the elastomeric body. The thermistor includes a thermistor tip that protrudes outside of the elastomeric body

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10818984B2Thermistor assembly including elastomeric body

Publication Date: 2020.10.27 FORD GLOBAL TECH LLC

AI summary

A thermistor assembly includes an elastomeric body, a thermistor housed at least partially inside the elastomeric body, and a thermistor tip that protrudes outside of the elastomeric body. The thermistor assembly may be used within a battery assembly of an electrified vehicle.