Spring Element Temperature Sensor for Battery Systems
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Solution Overview
Problem
Existing Li-ion battery systems face high costs and complexity in integrating temperature sensors due to rigid sensor designs, complex mechanical connections, and limited installation space, which complicates reliable temperature measurement and increases production expenses.
Innovation Solution
A temperature sensor with a spring element configuration, where at least one connection wire is designed as a helical or twisted spring, allowing for a reliable and cost-effective mounting mechanism that ensures consistent contact with the battery cell, using a spring force to maintain contact even under mechanical vibrations, and featuring a flexible design to accommodate varying spacings and installation constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid temperature sensors are used with complex mechanical connections (screws, soldering, rivets), then reliable temperature measurement is achieved, but device complexity and production costs increase
Solution Approach 1:
The patent applies the dynamics principle by replacing rigid mechanical connections with a flexible spring element that can dynamically adapt to spacing variations. The spring element compresses to establish thermal contact between the temperature sensor and battery cell, then maintains contact through elastic force while accommodating vibrations and thermal expansion, eliminating the need for complex rigid mounting structures.
Solution Approach 2:
The patent substitutes complex mechanical connection systems (screws, soldering, rivets) with a simplified spring-based mechanical system. The spring element replaces multiple fastening components and procedures with a single elastic element that provides both mounting and thermal contact functions, dramatically reducing device complexity.
2Measurement precision
If rigid temperature sensors are used to ensure optimum measurement, then measurement precision is maintained, but adaptability to varying spacings and installation constraints is reduced
Solution Approach 1:
The spring element provides dynamic adaptability by compressing to bridge spacing gaps between the temperature sensor and battery cell. This elastic compression mechanism allows the sensor to adapt to varying installation spacings and constraints while maintaining consistent thermal contact, enabling use in different battery configurations without sacrificing measurement precision.
Solution Approach 2:
The patent changes the mechanical parameter of the connection from rigid (fixed length) to elastic (variable length through compression). The spring element's ability to change its effective length through compression allows the system to adapt to different spacing parameters in various installation scenarios while maintaining measurement precision.
3Reliability
If complex modification of measuring site is performed for mechanical connection, then reliable thermal contact is achieved, but productivity and ease of manufacture decrease
Solution Approach 1:
The patent replaces complex mechanical modification procedures (screwing, soldering, riveting) with a simple spring-based compression mechanism. The spring element is installed in a single step and maintains thermal contact through elastic force without requiring any modification to the battery cell structure, dramatically improving production efficiency.
Solution Approach 2:
The spring element provides self-service by automatically establishing and maintaining thermal contact through its elastic properties. Once installed, the spring self-adjusts to maintain optimal contact pressure without requiring additional adjustment or modification procedures, enabling rapid assembly and improving productivity.
4Ease of manufacture
If standard temperature sensors are used in limited installation spaces, then cost is reduced, but adaptability to varying spacings is insufficient
Solution Approach 1:
The spring element serves multiple functions: it acts as both a mechanical mounting component and a thermal contact medium. This multi-functionality allows standard temperature sensors to be adapted to limited and varying installation spaces without requiring specialized sensor designs, maintaining cost-effectiveness while improving adaptability.
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 enables simple, cost-effective production and mounting of temperature sensors, ensuring reliable temperature measurement across varying configurations and limited spaces, reducing production costs and enhancing operational safety by maintaining consistent contact with battery cells.
Implementation Method 1
at least one spring element which is mechanically connected to the sensor head and is configured in such a manner that the sensor head is pressed by means of the spring element against a measuring site of the at least one battery cell
Data Source
AI summary
The invention relates to a temperature sensor (5) for measuring a temperature of a battery system (1) for storing electrical energy and also for supplying an electric motor of a motor vehicle with electrical energy. The temperature sensor (5) has a sensor head (6) and connection wires (7) electrically coupled to the sensor head. At least one of the connection wires (7) is at least partially formed as a spring element (8) or forms at least part of a spring element (8), wherein the spring element (8) is formed as a helical spring or as twisted. The invention further relates to a battery system (1) with at least one temperature sensor (5) for measuring a temperature of at least one battery cell (3), wherein the temperature sensor (5) has at least one spring element (8), which is mechanically attached to a sensor head (6) of the temperature sensor (5) and is fastened to the battery management system (4) in such a way that the sensor head (6) is pressed by the spring element (8) onto a measuring point (9) on a battery unit (2) of the battery system (1). The invention also relates to a method for fitting such a battery system (1).