Sensor Pin Elastic Deformation for Cylindrical Battery Temperature Monitoring
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Solution Overview
Problem
Existing battery systems with cylindrical cells face complexity in installing temperature sensors, particularly in larger packs, due to cumbersome fixation methods that complicate thermal management and lead to temperature deviations, affecting power generation and battery lifespan.
Innovation Solution
A battery system with a sensor pin arrangement where the pin insertion portion is deformed by neighboring cells to press a temperature sensor against the cell, eliminating the need for adhesives and providing a simple, reliable installation method, with the sensor connected to an electrical conductor element for monitoring by the BMS.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fixation methods (adhesives, mechanical fixtures) are used to install temperature sensors in battery packs, then the sensors can be securely fixed to monitor battery temperature, but the installation process becomes complex and time-consuming
Solution Approach 1:
The sensor pin utilizes the surrounding battery cells themselves to apply pressing force and secure the temperature sensor through elastic deformation of the pin's insertion portion, eliminating the need for external adhesives or mechanical fixtures. The system serves itself by using the battery pack's own structure to achieve sensor fixation.
Solution Approach 2:
The invention replaces complex mechanical fixation systems (adhesives, clips, screws) with a simple elastic deformation mechanism. The pin insertion portion deforms elastically under the natural pressing force of adjacent battery cells, creating a secure yet simple mounting solution that reduces installation complexity.
2Adaptability or versatility
If traditional fixation methods are used for temperature sensors, then sensors can be installed in various positions, but the installation time and production cost increase
Solution Approach 1:
The sensor pin is pre-designed with an elastic insertion portion that automatically deforms when inserted between battery cells. This preliminary design of the elastic structure allows for quick insertion without requiring additional fixation steps, reducing installation time while maintaining positioning flexibility.
Solution Approach 2:
The invention changes the physical state of the pin insertion portion from rigid to elastic, allowing it to deform and adapt to different battery cell arrangements. This parameter change enables versatile sensor placement while maintaining simple, rapid installation through the elastic deformation mechanism.
3Ease of manufacture
If temperature sensors are not properly contact with battery cells, then installation is simpler, but temperature measurement accuracy and heat transfer efficiency decrease
Solution Approach 1:
The invention replaces complex mechanical pressing mechanisms with a simple elastic deformation of the pin insertion portion. The elastic material naturally deforms under the gentle pressure of adjacent battery cells, ensuring consistent contact force that improves temperature measurement accuracy while keeping the installation process simple.
4Manufacturing precision
If complex fixation methods are used for temperature sensors, then sensor positioning is more precise, but the overall battery pack assembly complexity increases
Solution Approach 1:
The sensor pin automatically positions itself with precision by utilizing the elastic deformation of its insertion portion between battery cells. The surrounding cells provide the necessary constraining forces to achieve precise sensor positioning without requiring external positioning mechanisms, thereby maintaining assembly simplicity.
Solution Approach 2:
By changing the insertion portion from rigid to elastic, the system achieves precise sensor positioning through controlled deformation. The elastic parameter allows the pin to adapt to slight variations in battery cell positions while maintaining consistent contact, achieving precision without increasing overall assembly complexity.
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 allows for efficient temperature measurement and monitoring within the battery pack, ensuring optimal thermal management and extending battery lifespan by simplifying sensor installation and enhancing heat transfer.
Implementation Method 1
the pin insertion portion is deformed by neighboring battery cells when inserted into the clearance such that it presses the temperature sensor against at least one of the battery cells inside the clearance
Implementation Method 2
at least one temperature sensor arranged at the pin insertion portion for sensing the temperature of at least one of the battery cells
Data Source
Figure 1~2
Figure 3
AI summary
A battery system, comprising a battery pack (10) including a plurality of cylindrical battery cells (12) arranged in an array with clearances (14) between neighboring battery cells (12), an electrical conductor element (20) extending along a surface of the battery pack (10), and at least one sensor pin (16), the at least one sensor pin (16) comprising a pin head (17), a pin insertion portion (18) extending from the pin head (17) into the clearance (14), and at least one temperature sensor (22) arranged at the pin insertion portion (18) for sensing the temperature of at least one of the battery cells (12) and electrically connected to the electrical conductor element (20) via the pin head (17), wherein the pin insertion portion (18) is deformed by neighboring battery cells (12) when inserted into the clearance (14) such that it presses the temperature sensor (22) against at least one of the battery cells (12) inside the clearance (14).