Pouch Cell Battery Pack Core Housing for Accurate Thermal Sensing
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Solution Overview
Problem
Cordless power tool batteries require improved temperature monitoring and thermal management to enhance performance and safety, as existing solutions lack effective and durable methods for accurately measuring and dissipating heat within the battery pack.
Innovation Solution
A battery pack design incorporating a thermally conductive core housing with pouch cells, a flexible circuit, and temperature sensors (thermistors) coupled to copper traces, which extend into the core housing to accurately monitor temperature and facilitate heat dissipation, ensuring reliable operation and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is added to monitor battery temperature, then temperature monitoring accuracy is improved, but device complexity increases
Solution Approach 1:
The temperature sensor is integrated directly into the flexible circuit board, merging the sensing function with the existing circuit structure. This eliminates separate sensor housings and reduces the number of discrete components, thereby improving temperature monitoring accuracy while minimizing the increase in device complexity.
Solution Approach 2:
The flexible circuit board serves as an intermediary medium that carries both the temperature sensor and electrical connections. By using the flexible circuit as a substrate for the temperature sensor, the patent avoids adding complex mounting structures while achieving accurate temperature monitoring through direct contact with the battery cells.
2Temperature
If a thermally conductive core housing is used to dissipate heat, then heat dissipation efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The core housing is constructed from thermally conductive composite materials that combine structural integrity with heat dissipation properties. This allows the housing to serve dual functions as both a mechanical container and a thermal management component, improving heat dissipation efficiency while maintaining manufacturability through established composite material processing techniques.
Solution Approach 2:
The core housing is designed to perform multiple functions simultaneously: mechanical protection of battery cells, structural support, and active heat dissipation. By integrating thermal management functionality into the existing housing structure rather than adding separate cooling components, the patent improves heat dissipation while avoiding significant increases in manufacturing complexity.
3Reliability
If copper traces are extended into the core housing for temperature sensing, then temperature measurement reliability is improved, but electrical conductivity requirements increase
Solution Approach 1:
The copper traces for temperature sensing are merged with the power and signal transmission traces on the flexible circuit board. By using the same conductive pathways for both power delivery and temperature sensing, the patent improves temperature measurement reliability through direct electrical contact while avoiding the need for separate high-conductivity trace systems.
Solution Approach 2:
The flexible circuit board uses uniform copper trace geometry and material properties throughout, ensuring consistent electrical conductivity for both power transmission and temperature sensing functions. This homogeneity in electrical properties across different circuit functions simplifies the design and ensures reliable temperature measurements without requiring specialized high-conductivity trace configurations.
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 accurate temperature monitoring and efficient heat dissipation, enhancing the performance and safety of cordless power tool batteries by maintaining reliable operation and durability.
Implementation Method 1
the core housing is made from a thermally conductive material
Implementation Method 2
a temperature sensor operably coupled to the flexible circuit
Data Source
AI summary
A battery pack is disclosed and includes a battery housing, a core housing disposed within the battery housing, at least one pouch cell disposed within the core housing, a flexible circuit extending along an inner surface of the core housing, and a temperature sensor operably coupled to the flexible circuit.