Sensor Placement on Heater Lead Wire for Accurate Break Detection
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Solution Overview
Problem
Existing power storage devices face challenges in accurately determining the presence or absence of a broken heater wire, as the temperature of the sensor can be affected by the power storage cells, leading to potential false determinations.
Innovation Solution
A power storage device design that includes a sensor positioned apart from the pressing member and power storage cells, with the sensor placed on the heater lead wire and surrounded by a wound portion to prevent thermal interference, allowing for accurate temperature measurement of the heater wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor is disposed between the heater and the power storage cells to detect heater wire breaks, then the sensor can detect breaks, but the sensor is thermally affected by the power storage cells leading to false determinations
Solution Approach 1:
The sensor is extracted from the position between the heater and power storage cells and relocated to the heater lead wire. This separation removes the sensor from the thermal influence zone of the power storage cells, allowing accurate temperature measurement of the heater wire without false readings from cell heat.
Solution Approach 2:
The heater lead wire serves as an intermediary carrier for the sensor. By placing the sensor on the lead wire rather than between the heater and cells, the lead wire acts as a thermal buffer that isolates the sensor from direct thermal contact with the power storage cells while still allowing detection of heater wire temperature and breaks.
2Device complexity
If the sensor is placed close to the power storage cells for compact design, then device complexity is reduced, but the sensor is damaged by direct contact with external members
Solution Approach 1:
The sensor is merged with the heater lead wire structure, forming an integrated assembly where the sensor is mounted on the lead wire. This combination provides both mechanical support and thermal isolation, protecting the sensor from direct contact with power storage cells while maintaining a compact overall design.
Solution Approach 2:
The heater lead wire acts as a flexible protective carrier for the sensor. The lead wire's physical structure provides a protective barrier that prevents the sensor from directly contacting external members like power storage cells, reducing mechanical damage risk while maintaining flexibility in positioning.
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
Enables reliable detection of heater wire breaks and reduces sensor damage by isolating it from direct contact with external members, ensuring accurate temperature measurements and improved fault detection.
Implementation Method 1
when a current passes through the heater wire, the temperature of the heater wire increases
Implementation Method 2
the sensor can be restrained from being thermally affected by the power storage cell and can accurately measure the temperature of the heater wire
Data Source
AI summary
A power storage device includes at least one power storage cell, a heater that increases a temperature of the power storage cell, a pressing member that presses the heater against the power storage cell, and a sensor provided in the heater. The heater includes a base material and a heater wire provided on the base material. The base material includes a lead portion drawn from between the pressing member and the power storage cell. The heater wire includes a heater lead wire formed on the lead portion. The sensor is provided on the heater lead wire.