Flexible Thin Film Temperature Sensor Mounting for Battery Cells

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Solution Overview

Problem

Existing mounting structures for temperature sensors in battery packs are bulky, restrictive, and difficult to integrate into compact spaces due to their large size and weight, limiting their application in vehicles like electric vehicles.

Innovation Solution

A compact and lightweight temperature sensor mounting structure utilizing a flexible thin plate-like electric-wire with a chip-shaped temperature measuring component, a resin case, and moisture-proof material, which minimizes the size and thickness while ensuring reliable temperature detection and insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a substrate with conductive path and temperature measuring component is used, then temperature detection function is achieved, but the size and thickness of the mounting structure becomes large

Engineering Contradiction:

Improvetemperature detectionVSAvoidmounting structure size

Core Design Contradiction:

Measurement precisionVSVolume of moving object

Solution Approach 1:

The patent extracts the temperature measuring component from the traditional substrate structure and mounts it directly on the battery cell surface. The conductive path is also simplified to minimal necessary traces, removing unnecessary substrate layers and reducing the overall mounting structure volume while maintaining temperature detection capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs thin film structures for the conductive path and mounting configuration, replacing thick rigid substrates with thin flexible conductive layers. This approach significantly reduces the thickness and volume of the mounting structure while preserving the electrical connectivity and temperature sensing functions.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If core wires are connected by soldering to conductive path on substrate, then electrical connection is achieved, but the mounting structure becomes bulky and restrictive

Engineering Contradiction:

Improveelectrical connectionVSAvoidmounting flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent segments the electrical connection structure into separate functional elements: the temperature measuring component, the conductive path traces, and the mounting configuration. This segmentation allows each element to be optimized independently, enabling reliable electrical connection while achieving compact and flexible mounting that adapts to limited battery cell spaces.

Inventive Principle:

Principle #1Segmentation

3Object-affected harmful factors

If insulating resin material is applied to cover components, then insulation is achieved, but the thickness and weight of the structure increases

Engineering Contradiction:

ImproveinsulationVSAvoidmounting structure weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of stationary object

Solution Approach 1:

The patent uses thin film insulating structures and minimal resin material application to provide necessary insulation between conductive elements. This thin-film approach maintains electrical insulation functionality while dramatically reducing the weight and thickness compared to traditional bulk resin coating methods.

Inventive Principle:

Principle #30Flexible shells and thin films

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 enables efficient temperature measurement with reduced heat capacity and improved insulation, allowing for space-saving integration into battery cells, reducing component count, and achieving cost savings by eliminating the need for connectors.

Implementation Method 1

a moisture-proof material coating the temperature measuring component arranged in the resin case

Methodology Applied

Scientific EffectMoisture-proof coating: Coatings

Implementation Method 2

a resin case arranged on a periphery of the conductor exposed part and surrounding the temperature measuring component

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS20200014083A1Mounting structure of temperature sensor

Publication Date: 2020.01.09 YAZAKI CORP

AI summary

A mounting structure of a temperature sensor is configured to detect temperature of a battery cell included in a battery pack having a plurality of battery cells being connected by mounting on the battery cell. The mounting structure includes a flexible thin plate-like electric-wire including a conductor exposed part where the conductor is exposed, a chip-shaped temperature measuring component mounted on the conductor exposed part, a resin case arranged on a periphery of the conductor exposed part and surrounding the temperature measuring component, and a moisture-proof material coating the temperature measuring component arranged in the resin case.