Flat Cable Thermal Sensor for Battery Temperature Monitoring
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Solution Overview
Problem
Existing temperature measurement systems for rechargeable energy supply devices, such as battery packs, face challenges in achieving precise and timely temperature monitoring, especially during high-current charging, and require complex assembly processes that are not cost-effective.
Innovation Solution
A measuring arrangement where a thermal sensor element, such as an NTC or PTC resistor, is attached to a flat cable and positioned between the measurement object and its casing, allowing for simple and inexpensive assembly with direct mechanical contact for effective heat transfer, and optionally using multiple sensors at different positions for improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermal sensor element is attached directly to a battery cell using thermally conductive adhesive tape, then good heat transfer can be achieved, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines the thermal sensor element, flat cable, and electrical connection into a single integrated assembly. The sensor element is mounted on the flat cable with its contact surface facing the battery cell, eliminating the need for separate adhesive tape application and reducing assembly steps while maintaining thermal contact efficiency
Solution Approach 2:
The flat cable assembly serves multiple functions simultaneously: it provides electrical connection, mechanical support for the sensor element, and thermal conduction path. This multi-functionality reduces the number of separate components needed and simplifies the overall assembly process
2Reliability
If a conventional wired NTC resistor with housing is used, then the sensor is protected, but the design becomes bulkier and less flat
Solution Approach 1:
The patent removes the protective housing from the NTC resistor, exposing the sensor element directly. The flat cable itself provides mechanical support and protection, while the sensor element's contact surface is positioned to face the battery cell, achieving a flat profile suitable for thin battery pack designs
Solution Approach 2:
The flat cable acts as a flexible substrate that provides mechanical support for the sensor element without adding significant thickness. The cable's flexible nature allows it to conform to the battery cell surface while maintaining a low-profile design
3Measurement precision
If the thermal sensor element is positioned to ensure direct contact with the battery cell, then measurement precision improves, but the assembly process becomes more difficult
Solution Approach 1:
The sensor element is pre-positioned and fixed on the flat cable during manufacturing, with its contact surface oriented toward the battery cell. This preliminary positioning ensures correct orientation and contact during final assembly, eliminating the need for complex alignment procedures
Solution Approach 2:
The flat cable serves as an intermediary carrier that holds the sensor element in the correct position and orientation. By mounting the sensor on the cable rather than directly on the battery cell, the assembly process is simplified while maintaining precise thermal contact
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 solution enables precise and rapid temperature monitoring with a flatter design, ensuring good heat transfer and reducing assembly complexity while maintaining accuracy, even when the casing material is non-conductive like paper.
Implementation Method 1
good heat transfer can be guaranteed, since direct mechanical contact can be established between the thermocouple and the measurement object
Data Source
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AI summary
A measurement arrangement (34) for measuring a temperature of a rechargeable power supply device (10) for an electrical appliance, wherein the power supply device (10) has at least one measurement object (30), wherein at least one thermosensor element (28) is provided on a ribbon cable (26) and is arranged in a gap between the measurement object (30) and an outer sheath (32).