Embedded Thermocouple Bolt Fixture for Battery Cell Temperature Testing

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Solution Overview

Problem

Existing methods for measuring battery cell temperatures using thermocouples face issues such as tape adhesion failure in extreme environments, leading to inadequate measurements and potential battery degradation due to electrode compression and thermocouple breakage.

Innovation Solution

A thermocouple embedded testing device with a head, threaded, and hollow bolt body structure, incorporating a thermally insulating and conductive material, and a spring to secure the thermocouple within a fixture assembly, ensuring stable contact and preventing degradation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If tape is used for attachment of thermocouple to battery cell, then thermocouple can be attached to battery cell, but tape adhesion reduces in high or low-temperature environments and high humidity environment, disrupting attachment and resulting in inadequate temperature measurement

Engineering Contradiction:

Improveattachment reliabilityVSAvoidtemperature measurement accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent introduces a specialized attachment mechanism that acts as an intermediary between the thermocouple and battery cell. This mechanism includes a compression element that applies controlled force to maintain thermocouple contact with the battery cell surface, eliminating the reliance on tape adhesion that fails in extreme environments. The compression element serves as a mediator that ensures reliable mechanical and thermal contact regardless of temperature or humidity conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If thermocouple is placed between battery cell and aluminum fixture, then thermocouple is secured during testing, but this leads to degradation of battery cell due to electrode compression and thermocouple breakage from repeated stress

Engineering Contradiction:

Improvethermocouple securementVSAvoidbattery cell degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by creating a specialized localized structure at the thermocouple attachment point. The compression element is designed with specific geometric features and material properties that concentrate the securing function at the exact location where thermocouple contact is needed, while distributing compressive forces away from sensitive battery cell regions. This localized approach allows secure thermocouple mounting without subjecting the entire battery cell to degrading compression forces.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent implements beforehand cushioning by incorporating compliant or damping elements in the attachment mechanism that absorb and mitigate repeated mechanical stress before it reaches the thermocouple and battery cell. These cushioning elements are pre-positioned to protect vulnerable components from fatigue and breakage during repeated charge-discharge cycles, eliminating the need for harsh securing methods that cause degradation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of operation

If thermocouple with thin wire-like shape is used, then thermocouple can be positioned for measurement, but it is susceptible to breakage from repeated stress when placed between battery cell and aluminum fixture

Engineering Contradiction:

Improvethermocouple positioningVSAvoidthermocouple durability

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent applies parameter changes by modifying the mechanical environment of the thin-wire thermocouple through the attachment mechanism. The compression element and supporting structure alter the stress distribution parameters, transforming concentrated point loads into distributed forces that the thin thermocouple wire can withstand. This parameter modification allows the use of fine-gauge thermocouples for precise positioning while preventing breakage through controlled stress management.

Inventive Principle:

Principle #35Parameter changes

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 provides secure and accurate temperature measurements by maintaining contact with the battery cell, reducing degradation, and enhancing sensitivity, especially in challenging conditions.

Implementation Method 1

the thermocouple embedded testing device may ensure contact is maintained between the thermocouple and the battery cell, thus increasing thermocouple sensitivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250314537A1Systems and methods for a thermocouple embedded testing device

Publication Date: 2025.10.09 FORD GLOBAL TECH LLC

AI summary

Methods and systems are provided for thermocouple embedded testing devices that may be incorporated into a fixture assembly for temperature testing of battery cells to prevent degradation of thermocouples. In one example, a thermocouple embedded testing device may comprise a bolt including a head portion filled with a first material and a threaded portion filled with a second material, and a thermocouple positioned within the bolt and extending from the head portion to the threaded portion.