Flexible Thermal Sensing Structure for EV Battery Contact
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Solution Overview
Problem
Conventional thermal sensing structures for electric vehicle batteries are bulky, expensive, and inflexible, making it difficult to connect multiple thermal sensors and maintain press-contact with the battery while reducing stress on insulating sheets and circuits.
Innovation Solution
A flexible insulating sheet with a flexible circuit and an elastic insulating resin covering the thermal sensor and connection parts, allowing the structure to bend smoothly and maintain contact with the battery, increasing sensing accuracy and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a hard circuit board is used, then structural stability is improved, but device size increases and manufacturing cost increases
Solution Approach 1:
The patent replaces the hard circuit board with a flexible printed circuit board (FPC) that has insulating properties. This FPC maintains structural stability for circuit connections while being thin and flexible enough to conform to battery surfaces, thereby reducing overall device size and manufacturing cost compared to rigid circuit boards.
Solution Approach 2:
The patent uses a composite structure combining the flexible printed circuit board with insulating resin material. The FPC provides structural stability and circuit functionality, while the insulating resin adds thermal insulation and mechanical support, creating a composite solution that achieves stability without requiring a bulky hard circuit board.
2Reliability
If lead wires with protective tubes are used, then electrical insulation is improved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent integrates the insulating function into the flexible printed circuit board itself and the insulating resin material, eliminating the need for separate protective tubes around lead wires. The FPC provides both structural support and electrical insulation, while the insulating resin covers the thermal sensor and connections, simplifying the overall structure and reducing manufacturing complexity.
Solution Approach 2:
The flexible printed circuit board serves multiple functions: it provides structural stability, electrical insulation, and mechanical flexibility. The insulating resin also serves dual purposes by insulating the thermal sensor and providing mechanical protection. This multi-functionality eliminates the need for separate protective tube components.
3Reliability
If two insulating sheets are used to cover lead wires, then electrical insulation is improved, but flexibility decreases and manufacturing time increases
Solution Approach 1:
The patent replaces two separate insulating sheets with a single flexible printed circuit board that has inherent insulating properties. The FPC is thin and flexible, allowing it to conform to curved battery surfaces without requiring multiple layers, thereby maintaining electrical insulation while improving flexibility and reducing manufacturing steps.
Solution Approach 2:
The patent uses a composite approach where the flexible printed circuit board and insulating resin work together to provide electrical insulation. This composite structure achieves the required insulation level with a single flexible layer rather than two separate sheets, maintaining adaptability to battery shapes while simplifying the manufacturing process.
4Adaptability or versatility
If insulating sheets are forced to bend, then adaptability to curved surfaces is improved, but stress on insulating sheets and circuits increases
Solution Approach 1:
The patent uses a flexible printed circuit board that is inherently designed to be bent and conform to curved surfaces. The FPC's flexibility allows it to adapt to battery shapes without forcing the material beyond its elastic limits, thereby maintaining adaptability while minimizing stress and preventing damage to the circuit traces and connections.
Solution Approach 2:
The patent employs a dynamic, flexible design where the FPC can elastically deform to match the battery surface geometry. This dynamic adaptability allows the structure to conform to curved surfaces through controlled bending within elastic limits, avoiding the excessive stress that would occur with rigid or overly stiff materials forced into curved configurations.
5Reliability
If wide insulating films are used, then electrical insulation is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses a flexible printed circuit board with integrated insulating properties that provides adequate electrical insulation without requiring excessively wide coverage. The FPC's design optimizes the insulating area to the minimum necessary for electrical isolation, reducing material usage and manufacturing cost while maintaining sufficient insulation reliability for the application.
Solution Approach 2:
The patent employs a composite structure where the flexible printed circuit board and insulating resin work together to provide electrical insulation. This division of insulating functions between two materials allows for optimized coverage areas, reducing the total amount of insulating material required compared to using a single wide insulating film, thereby lowering manufacturing costs while maintaining insulation reliability.
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 a compact, cost-effective thermal sensing structure that ensures accurate temperature sensing by maintaining a flat contact surface with the battery, reducing stress on the insulating sheet and circuit, and allowing easy adaptation to curved surfaces.
Implementation Method 1
an elastic insulating resin covering integrally the thermal sensor and the connection parts
Implementation Method 2
The thermal sensor 43 is brought into contact with a battery 47 via the resin material 45 and an upper wall 46 of the case 41 to sense the temperature of the battery 47
Data Source
AI summary
Flexible circuits 2, 3 are formed on a flexible insulating sheet 1. A thermal sensor 4 is connected between the circuits 2, 3. The thermal sensor 4 and connecting parts 5 are integrally covered with an elastic insulating resin 6. While the insulating sheet 1 is bent together with the insulating resin 6, the thermal sensor 4 is pushed onto an object to be sensed 8 via the insulating sheet 1. A plurality of thermal sensors 4 are connected in series in a longitudinal direction of the insulating sheet 1. The insulating resin 6 covers the thermal sensors 4 and the connecting parts 5.