Flex Foil Substrate Connector for Battery Voltage and Temperature Sensing
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Solution Overview
Problem
The placement and attachment of temperature sensors on busbars in battery systems can lead to short circuits due to external forces, especially when near ultrasonic weld locations, compromising accurate temperature measurement and reliability.
Innovation Solution
A flex foil substrate with a conductive layer and trace pattern is used to connect temperature sensors to busbars, positioning them away from weld locations to prevent damage and ensure accurate temperature measurement, while also reducing wire requirements and enhancing reliability by combining voltage and temperature sensing traces on a common substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are placed directly on busbars near ultrasonic weld locations, then temperature measurement accuracy is improved, but the risk of short circuits and sensor damage increases due to external forces
Solution Approach 1:
The patent introduces a flex foil substrate as an intermediary component between the temperature sensor and the busbar. The substrate positions the temperature sensor in close proximity to the busbar for accurate temperature measurement while maintaining a safe distance from the ultrasonic weld locations, thus preventing short circuits and sensor damage caused by external forces during welding operations
2Measurement precision
If multiple separate connections are made for voltage and temperature sensing, then measurement accuracy is maintained, but device complexity and wire requirements increase
Solution Approach 1:
The patent merges voltage sensing traces and temperature sensing traces onto a single flex foil substrate. This integration allows both voltage and temperature measurements to be performed simultaneously through the same substrate structure, reducing the number of separate wires and connections needed while maintaining the accuracy of both measurement functions
3Reliability
If temperature sensors are positioned away from weld locations, then reliability is improved by preventing short circuits, but measurement accuracy may be compromised
Solution Approach 1:
The flex foil substrate enables different regions to serve different functions: one region positions the temperature sensor close to the busbar for accurate temperature measurement, while another region maintains adequate distance from ultrasonic weld locations to prevent short circuits. This spatial differentiation of functional requirements on the same substrate resolves the contradiction between reliability and measurement precision
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 protects temperature sensors from damage, allows for accurate battery temperature measurement, and increases the reliability of battery system connectivity by positioning sensors away from potential short circuits and reducing wire components.
Implementation Method 1
The temperature sensor is attached to the first trace and the second trace using conductive adhesive
Implementation Method 2
the busbar is attached to the first cover layer of the flex foil substrate using pressure sensitive adhesive
Implementation Method 3
The third trace of the flex foil substrate is ultrasonically welded to the third trace
Data Source
AI summary
A sensing system for a battery includes a flex foil substrate including a first cover layer. A conductive layer defines a trace pattern including traces. A second cover layer defines a first opening. The conductive layer is sandwiched between the first cover layer and the second cover layer. The first opening exposes a first trace and a second trace of the trace pattern. A busbar is attached to the first cover layer of the flex foil substrate. A temperature sensor is connected to the first trace and the second trace of the trace pattern in the first opening of the first cover layer.