Modular Battery Pack Temperature Sensing for Low-Cost Replacement
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Solution Overview
Problem
Existing battery pack temperature acquisition systems require the entire flexible printed circuit board to be replaced during maintenance, leading to high maintenance costs and inconvenience due to the inability to separately replace components like fuses and temperature sensors, and the manufacturing process involves high-temperature welding, increasing costs.
Innovation Solution
A battery pack temperature acquisition module with a modular design featuring a temperature sensing element, connection terminal, and insulation body, allowing for separate replacement and connection via crimping instead of high-temperature welding, reducing maintenance costs and simplifying installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reflow welding, tin welding, ultrasonic welding or laser welding is used to weld components to the flexible printed circuit board, then reliable electrical connection is achieved, but high-temperature resistant protective film must be added to prevent damage to the flexible printed circuit board, greatly increasing manufacturing cost
Solution Approach 1:
The patent divides the temperature acquisition system into separate modular components: the temperature sensor element and the flexible printed circuit board are independent parts that can be separately manufactured and assembled. This segmentation eliminates the need for high-temperature welding processes that would require expensive heat-resistant protective films, while still achieving reliable electrical connection through the modular interface.
2Reliability
If the entire flexible printed circuit board is replaced during maintenance, then complete functionality is restored, but maintenance cost increases and convenience decreases due to inability to separately replace components
Solution Approach 1:
The temperature sensor element is designed as a separate replaceable module from the flexible printed circuit board. When the temperature sensor fails, only the sensor element needs to be replaced rather than the entire circuit board, significantly reducing maintenance costs and improving repair convenience while maintaining complete system functionality.
Solution Approach 2:
The patent enables selective replacement of the temperature sensor element while retaining the reusable flexible printed circuit board. This approach recovers the value of the circuit board component, reducing waste and lowering overall maintenance expenses by discarding only the failed sensor element rather than the entire assembly.
Data Source
AI summary
The present invention provides a battery pack temperature acquisition module and system. The battery pack temperature acquisition module has: an insulation body; a temperature sensing element mounted on the insulation body and configured to detect a temperature of a battery cell; and a connection terminal mounted on the insulation body. The temperature sensing element has a lead for transmitting a temperature signal, one end of the connection terminal is electrically connected with the lead of the temperature sensing element, and the other end is adapted to be connected to a signal acquisition line to electrically connect the temperature sensing element to the signal acquisition line, the connection terminal and the insulation body are respectively formed. In the present invention, the battery pack temperature acquisition module can be replaced separately without replacing the signal acquisition line, which improves the convenience of use and reduces the later maintenance cost.