Low Profile Sensor for Battery Cell Condition Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery packs face challenges in attaching sense leads and discrete devices to ultra-thin single electrode pair electrochemical cells due to bulkier sense leads, making it difficult to sense cell conditions effectively.
Innovation Solution
A low-profile sensor device with a solid state device or series of solid state devices on a common carrier, utilizing a flexible circuit board and semiconductor components to externally mount battery cell sensing electronics, allowing for voltage and temperature sensing and active state of charge balancing without external wiring, and embedding sensors within the sealing material between electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional sense leads and discrete devices are used to attach to ultra-thin single electrode pair electrochemical cells, then the cell structure remains simple, but the bulkier sense leads make it difficult to sense cell conditions effectively and increase device complexity
Solution Approach 1:
The patent combines the sensing electronics, communication device, and energy storage components into a single integrated sensor device that attaches to the battery cell. This merging eliminates the need for separate sense leads and discrete devices, solving the problem of bulky attachments while maintaining effective cell condition sensing through integrated solid state devices on a common carrier.
Solution Approach 2:
The patent replaces conventional mechanical sense leads with a low-profile sensor device featuring solid state devices and a flexible circuit board. This substitution eliminates bulky mechanical connections while enabling effective voltage and temperature sensing through electronic integration, directly addressing the contradiction between sensing precision and device complexity.
2Adaptability or versatility
If a low-profile sensor device with solid state devices is used, then cell condition sensing and state of charge balancing are improved, but the device complexity increases due to integrated electronics
Solution Approach 1:
The sensor device is designed to perform multiple functions including voltage sensing, temperature sensing, state of charge balancing, and communication. By integrating these diverse functions into a single device with solid state devices on a common carrier, the patent achieves high adaptability and versatility while managing complexity through functional integration rather than separate components.
Solution Approach 2:
The patent employs a nested structure where solid state devices are mounted on a common carrier which itself is integrated into the sensor device housing. This nesting approach organizes complex components in a hierarchical manner, allowing multiple sensing and control functions to coexist within a compact form factor, thereby improving versatility while containing device complexity.
3Length of stationary object
If sense leads are made thinner to match ultra-thin cell profile, then the aesthetic and space constraints are improved, but the manufacturing precision and reliability of connections deteriorate
Solution Approach 1:
The patent uses a flexible circuit board as the carrier for solid state devices, enabling the sensor device to achieve ultra-thin profile comparable to the battery cell thickness. This flexible film approach maintains structural integrity and connection reliability while matching the thin form factor requirements, avoiding the manufacturing precision issues associated with excessively thin rigid sense leads.
Data Source
AI summary
An electrochemical cell has a flexible low-profile sensor device that includes a solid state device or series of solid state devices on a common carrying material that enable the device(s) to sense battery cell conditions and actively perform cell control functions. At least a portion of the sensor device resides outside the cell. When arranged in a stack, cells including the sensor automatically form a communication network.