Spring-Loaded Sensor Mounting for Battery Case Tolerance Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing sensor mounting structures for battery cells in electric vehicles are complex due to size tolerances between the battery and baseplate, leading to potential displacement and reduced accuracy in temperature measurements, which complicates the mounting process and affects measurement accuracy.
Innovation Solution
A simplified sensor mounting structure that attaches a temperature sensor directly to the battery case using an insulator and a spring mechanism, eliminating the need for a baseplate, ensuring proper contact and accuracy through a locking mechanism and adjustable spring portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a baseplate is used to mount the temperature sensor on the battery case, then the sensor can be securely mounted, but the overall mounting structure becomes complicated
Solution Approach 1:
The patent removes the baseplate from the mounting structure, extracting the unnecessary intermediate component. The temperature sensor is mounted directly to the battery case using only the covering portion with locking portions, simplifying the overall structure while maintaining secure mounting through the elastic portions that provide locking engagement.
Solution Approach 2:
The patent merges the functions of the baseplate and the covering portion into a single integrated component. The covering portion directly performs both the mounting and securing functions that were previously divided between the baseplate and covering portion, eliminating structural complexity.
2Ease of manufacture
If separate size tolerances are allowed for the battery and baseplate, then manufacturing is easier, but displacement occurs between the battery and thermistor reducing measurement accuracy
Solution Approach 1:
The patent introduces dynamic elements through the elastic portions that can deform and adapt to dimensional variations. The elastic portions act as flexible connectors that accommodate tolerance differences between the battery case and sensor mounting features, maintaining secure engagement and proper sensor positioning despite manufacturing variations.
Solution Approach 2:
The patent changes the physical state of the locking portions from rigid to elastic, allowing them to deform within a certain range to compensate for dimensional variations. This parameter change enables the structure to absorb tolerance variations while maintaining measurement accuracy.
3Measurement precision
If the spring stroke of the flexible portions is increased to prevent displacement, then measurement accuracy is maintained, but the mounting structure becomes more complicated
Solution Approach 1:
The patent removes the separate spring component from the mounting structure, extracting the unnecessary intermediate element. The elastic portions directly integrated into the covering portion provide the necessary flexibility and spring action without requiring a separate spring mechanism, simplifying the overall structure while maintaining measurement accuracy.
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 configuration simplifies the sensor mounting process, maintains accurate temperature measurements, and compensates for size tolerances, enhancing the reliability of temperature monitoring in battery cells.
Implementation Method 1
The spring portion presses the temperature sensing portion to hold the temperature sensing surface in close contact with the wall of the case
Data Source
AI summary
A sensor mounting structure includes an insulator and a temperature sensor. The insulator is attached to a wall of a case of an electric storage component to hold an electrode terminal projecting from the case and insulating the electrode terminal from the case. The temperature sensor includes a temperature sensing portion, a locking portion, and a spring portion. The temperature sensing portion holds a temperature sensing component and includes a temperature sensing surface that contacts the wall of the case. The locking portion is locked to the insulator. The spring portion presses the temperature sensing portion to hold the temperature sensing surface in close contact with the wall of the case.