Inverted Temperature Sensor Mounting for Power Relay Bus Bars

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Solution Overview

Problem

Conventional temperature sensing methods in power relay assemblies for electric vehicle battery systems are inefficient due to heat generation at positions other than the sensing surface, leading to decreased response rates and reliability, and the clinching method for nut attachment can cause the temperature sensing surface to lift, complicating quality control.

Innovation Solution

A temperature sensor installing device with a body housing featuring a temperature sensor insertion recess and a nut insertion recess, allowing the temperature sensor to face upward and the nut to be inserted through press fitting, insert molding, or bonding, minimizing heat transfer and providing a stable fastening mechanism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the temperature sensor is mounted with the sensing surface facing the heating surface using a clinching method, then the mounting structure is simplified, but the temperature measurement responsiveness decreases and measurement accuracy is reduced

Engineering Contradiction:

Improvemounting structureVSAvoidtemperature measurement responsiveness

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The temperature sensor is inverted so that its sensing surface faces away from the heating surface (facing upward) instead of facing the heating surface directly. This inversion allows the sensor to measure temperature through thermal conduction from the bus bar without being subjected to direct heat exposure and mechanical lifting forces, thereby improving measurement responsiveness and accuracy while maintaining simple mounting structure

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The bus bar serves as an intermediary thermal conduction medium between the heating surface and the temperature sensor. The sensor measures temperature by detecting thermal conduction through the bus bar rather than direct exposure to the heating surface, which resolves the contradiction by improving measurement accuracy while keeping the mounting structure simple

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the temperature sensor mounting ring is coupled to the bus bar using a mounting bolt with clinching method, then the mounting process is simplified, but the sensing surface may lift up reducing reliability

Engineering Contradiction:

Improvemounting processVSAvoidsensing surface contact reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The temperature sensor is inverted and positioned such that the sensing surface faces upward away from the heating surface. This inversion eliminates the problem of sensing surface lifting because the sensor body, not the sensing surface, contacts the mounting structure. The sensing surface remains in stable contact with the bus bar through thermal conduction without being subjected to mechanical lifting forces during tightening

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The temperature sensor mounting ring is separated from direct contact with the heating surface and bus bar. The mounting ring is coupled to the bus bar using a clinching method that prevents lifting, while the temperature sensor itself is positioned independently with its sensing surface facing upward, extracting the sensing function from the mechanical mounting structure to eliminate the lifting problem

Inventive Principle:

Principle #2Taking out (Extraction)

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 improves temperature measurement responsiveness, reliability, and structural stability while reducing costs by minimizing heat dissipation and eliminating the need for clinching, thus enhancing measurement accuracy and operational convenience.

Implementation Method 1

A temperature sensor 40 is attached onto a bus bar 20... to measure such a temperature

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

At least a portion of the body housing may be formed as a hollow chambered structure... minimizing heat transfer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11506543B2Temperature sensor installing device and method for power relay assembly

Publication Date: 2022.11.22 HYUNDAI MOBIS CO LTD

AI summary

A temperature sensor installing device for a power relay assembly is configured to be attached to a lower surface of a bus bar attached to a heating surface of the power relay assembly. The temperature sensor installing device includes: a body housing; a temperature sensor insertion recess formed in an upper portion of the body housing and accommodating a temperature sensor such that a temperature sensing surface of the temperature sensor faces upward; and a nut insertion recess formed in the upper portion of the body housing and accommodating a nut.