Thermistor Attachment Stability in Battery Pack Protection Circuit Modules
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Solution Overview
Problem
Conventional battery packs face safety issues due to thermistors becoming displaced by physical shock, leading to defective operation and structural integrity challenges during assembly, which compromises the accuracy of temperature sensing and safety.
Innovation Solution
A battery pack design where the thermistor is firmly attached to the protection circuit module using a support and insulating film-covered lead wires, ensuring secure attachment and accurate temperature sensing, preventing separation under external shock and enhancing assembly workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thermistor is attached to the protection circuit module using conventional methods, then the assembly process is simple, but the thermistor becomes displaced due to physical shock causing defective operation
Solution Approach 1:
The attachment structure is divided into distinct functional segments: the support member provides mechanical anchoring, the insulating film provides electrical isolation, and the adhesive secures the thermistor. This segmentation allows each component to perform its specific function optimally while maintaining overall reliability.
Solution Approach 2:
The attachment system uses a composite structure combining the support member (providing mechanical strength), insulating film (providing electrical insulation), and adhesive (providing bonding). This composite approach ensures both mechanical stability and electrical safety, preventing thermistor displacement while maintaining operational reliability.
2Reliability
If the thermistor is firmly attached to ensure stability, then reliability improves, but manufacturing complexity increases
Solution Approach 1:
The support member and insulating film are prepared and positioned in advance before the thermistor is attached. This preliminary preparation ensures that when assembly occurs, the components are already in their correct positions and orientations, making the final attachment step straightforward and reliable.
Solution Approach 2:
The support member acts as an intermediary between the protection circuit module and the thermistor, providing a dedicated mounting structure. The insulating film serves as an intermediary layer that facilitates both electrical isolation and mechanical bonding. These intermediaries simplify the overall assembly process by providing clear, dedicated interfaces.
3Object-affected harmful factors
If the thermistor is securely fixed to prevent displacement, then safety improves, but the attachment process becomes more complex
Solution Approach 1:
The insulating film serves as a cushioning layer between the thermistor and the protection circuit module, providing both electrical isolation and mechanical compliance. This preliminary cushioning structure protects the thermistor from direct mechanical shocks while maintaining its secure attachment position.
Solution Approach 2:
The insulating film is a thin, flexible structure that conforms to the surfaces it connects, providing reliable electrical isolation while accommodating minor dimensional variations. This thin film structure maintains secure attachment without adding significant complexity to the overall device.
4Productivity
If the thermistor attachment structure is simplified for easy manufacturing, then productivity improves, but temperature sensing accuracy decreases
Solution Approach 1:
The temperature sensing function is extracted and isolated to the thermistor itself, while the attachment structure (support member and insulating film) is designed solely to secure and isolate the thermistor electrically. This separation ensures that the sensing function remains pure and accurate, while the attachment structure remains simple and manufacturable.
Solution Approach 2:
The insulating film acts as an intermediary that maintains the precise positioning of the thermistor relative to the protection circuit module while providing electrical isolation. This intermediary structure enables accurate temperature sensing without requiring complex attachment mechanisms, as the film naturally maintains consistent spacing and positioning.
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 a secure and accurate temperature sensing mechanism, enhancing the safety and structural integrity of the battery pack by preventing thermistor separation and improving manufacturing efficiency.
Implementation Method 1
a thermistor (30) that senses the temperature of the bare cells (10)
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5B
AI summary
The present invention relates to a battery pack (100) including: a plurality of battery cells (10) connected in series or in parallel; and a protection circuit module (20) that is electrically connected with the bare cells (10) and where a thermistor (30) that senses the temperature of the bare cells (10) is attached, in which the thermistor (30) has an opposite side (34) that is substantially perpendicularly opposite to an edge (22) of the protection circuit module (20) and a support (40) is disposed between the opposite side (34) of the thermistor (30) and the protection circuit module (20).