Temperature sensor mounting arrangement for a battery frame assembly

1. A temperature sensor mounting arrangement in a battery frame assembly comprising:

a plurality of serially arranged battery frames arranged in a side by side configuration;

end frames arranged at opposing ends of said battery frame assembly;

a plurality of rechargeable battery packs supportively retained and electrically interconnected within said battery frame assembly therein;

said temperature sensor mounting arrangement comprising:

an elongated support member secured to a frame member, said frame member consisting of one of said battery frames or end frames,

wherein said support member extends from a peripheral portion of said frame member into an interior region of said frame member;

at least one electrical interface connector secured to a first end of said support member;

an electronic temperature sensor device positioned and secured at a face of said support member, wherein said support member specifically positions and supports said temperature sensor device proximate to an outer surface of one of said battery packs, said specific positioned temperature sensor responsive to temperature at said battery outer surface;

a plurality of electrical conductors arranged on at least one face of said support member electrically connecting said at least one interface connector to said temperature sensor device electrically communicating said measured temperature as an electrical signal to said interface connector;

wherein said temperature sensor mounting arrangement maintains said temperature sensor specifically positioned relative to said battery pack outer surface, providing repeatable temperature measurements between said sensors frame to frame; and

wherein said elongated support member with said temperature sensor and electrical connectors are a one-piece modular unit subassembly configured for high speed mounting to said frame member.

2. The temperature sensor mounting arrangement of claim 1 , wherein said end frame further comprises:

a rigid end plate having a plurality of grooves or ridges formed therein, said grooves or ridges configured to add rigidity to said end plate;

wherein said elongated support member extends proximate parallel to a portion of said end plate; and

wherein portions of said grooves and ridges are partially collapsed in a region over which said support member extends, wherein said partially collapsed region receives said elongated support member within a thickness of said end plate enabling a tight fitting space saving assembly between said end plate and a neighboring one of said battery packs.

3. The temperature sensor mounting arrangement of claim 1 , wherein

an electrically insulating sheet is arranged between said support member and said proximate outer surface of said battery pack; and

wherein said insulating sheet is secured to said frame member in unison with said support member.

4. The temperature sensor mounting arrangement of claim 3 , wherein said insulating sheet includes an opening therethrough provided in a location proximate to said temperature sensor device and between said temperature sensor device and said proximate outer surface of said battery pack, said opening configured to reduce response time of said temperature sensor.

5. The temperature sensor mounting arrangement of claim 1 , wherein

said support member is formed of an electrically insulating material;

wherein said support member includes an electrically conductive metallic sheet secured to a face of said support member;

wherein said electrical conductors are formed by etchably or chemically removing portions of said electrically conductive sheet; and

wherein said temperature sensor device and at least one electrical connector are electrically conductively bound to said electrical conductors by soldering.

6. The temperature sensor mounting arrangement of claim 1 , wherein said support member is substantially rigid.

7. The temperature sensor mounting arrangement of claim 1 , wherein said temperature sensor is configured to provide a correlated change in electrical resistance in relationship to changes in said measured temperature.

8. The temperature sensor mounting arrangement of claim 1 , further comprising a silicone based potting material encapsulating and protecting said temperature sensor on said support member.

9. The temperature sensor mounting arrangement of claim 1 , wherein said support member is secured to said frame member by at least one thermally activated mounting member adapted for high speed assembly.

10. The temperature sensor mounting arrangement of claim 9 , wherein said at least one thermally activated mounting member comprises heat stakes.

11. The temperature sensor mounting arrangement of claim 1 , wherein said measured temperature is communicated through said at least one electrical interface connector to a controller device operable to regulate at least one of battery charging current and battery coolant flow according to said measured temperature.