Lithium-ion battery impending failure detection

Abstract

A battery management system configured to detect an impending failure of a lithium-ion battery cell includes a sensor array microchip. The microchip includes a plurality of silicon chemically sensitive field effect transistors (CS-FETs) configured to detect a plurality of different gases exhausted by the lithium-ion battery cell. The battery management system also includes a battery monitoring unit (CMU) configured to receive data indicating a detected amount of gas exhausted by the lithium-ion battery cell from at least one of the CS-FETs. The CMU is further configured to compare the data indicating the detected amount of the exhausted gas with a predetermined threshold amount of a target exhausted gas programmed into the CMU. The CMU is further configured to trigger a signal indicating an impending failure of the lithium-ion battery cell when the detected amount of the exhausted gas exceeds the predetermined threshold amount of the target exhausted gas.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 62 / 979,322, filed on February 20, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure generally relates to systems and methods for detection of impending failure of lithium-ion battery cells. Background Art

[0004] An electrical energy storage or battery system or array may include multiple battery cells in relatively close proximity to each other. Multiple battery cells may be assembled into a battery stack or module, and multiple battery modules may be assembled into a battery pack. Batteries can be broadly classified as primary batteries and secondary batteries. Primary batteries, also called disposable batteries, are intended to be used until exhausted and then simply replaced with new batteries. Secondary batteries, often called rechargeable batteries, employ specific high-energy chemistries that allow such batteries to be repeatedly charged and reused, thus offering economical, environmentally friendly, and easy-to-use advantages over disposable batteries.

[0005] Rechargeable batteries are used to power a variety of items such as toys, consumer electronics, and automobiles. In extreme cases, the special chemistry of rechargeable batteries such as lithium-ion batteries, as well as external factors, can cause internal reaction rates to generate large amounts of heat energy, resulting in thermal events. As the reactions within rechargeable batteries accelerate, many such batteries also off-gas before catastrophic battery failure. The safety of rechargeable batteries is an important issue in a variety of applications such as automotive, aviation, and consumer electronic devices like smartphones and laptops. Safety issues are particularly prominent in electric vehicles as the demand for fast-charging and long-range vehicles is growing, increasing the number of batteries within the target vehicle. Summary of the invention

[0006] A battery management system configured to detect an impending failure of a lithium-ion battery cell includes a sensor array microchip. The microchip includes a plurality of silicon chemically sensitive field effect transistors (CS-FETs) configured to detect a plurality of different gases exhausted by the lithium-ion battery cell. The battery management system also includes a cell monitoring unit (CMU) configured to receive data indicating a detected amount of gas exhausted by the lithium-ion battery cell from at least one of the CS-FETs. The CMU is further configured to compare the data indicating the detected amount of the exhausted gas with a predetermined threshold amount of a target exhausted gas programmed into the CMU. The CMU is further configured to trigger a signal indicating an impending failure of the lithium-ion battery cell when the detected amount of the exhausted gas exceeds the predetermined threshold amount of the target exhausted gas.

[0007] The CMU may also be configured to determine when the lithium-ion battery cell is connected to the battery charger. In such an embodiment, the CMU may be further configured to electrically disconnect the lithium-ion battery cell from the battery charger in response to the detected amount of exhaust gas exceeding a corresponding predetermined threshold amount of the target exhaust gas.

[0008] The CMU may also be configured to determine when the lithium-ion battery cell is connected to the electrical load. The CMU may also be configured to disconnect the lithium-ion battery cell from the electrical load in response to the detected amount of exhaust gas exceeding a corresponding predetermined threshold amount of the target exhaust gas.

[0009] The battery management system may additionally include a fire suppression system configured to extinguish an electrical fire. In such an embodiment, the CMU may also be configured to activate the fire suppression system in response to the detected amount of exhaust gas exceeding a corresponding predetermined threshold amount of the target exhaust gas.

[0010] The CS-FETs can be arranged side by side in a single plane on a sensor array microchip. In addition, each CS-FET can be configured to detect one of the gases exhausted by the lithium-ion battery cells.

[0011] Each detected gas exhausted by the lithium-ion battery cell can be selected from a list including hydrogen (H2), carbon dioxide (CO2), carbon monoxide (CO), and ethylene (C2H4). In addition, the predetermined threshold amount programmed into the CMU can be selected from 10 ppm of H2, 500 ppm of CO2, 10 ppm of CO, and 10 ppm of C2H4.

[0012] The lithium-ion battery cell may be part of a multi-cell rechargeable energy storage system (RESS) having multiple lithium-ion battery cells arranged in separate battery modules. In such an embodiment, the sensor array microchip may be arranged within the RESS and in proximity to the individual battery modules. Furthermore, the sensor array microchip may be configured to detect a variety of different gases exhausted by the lithium-ion battery cells at the module level.

[0013] The lithium-ion battery cell may include a housing having a vent configured to vent gases. In such an embodiment, the sensor array microchip may be arranged proximate to the vent.

[0014] The lithium-ion battery housing may be configured as one of a pouch-shaped housing, a prismatic housing, and a cylindrical housing.

[0015] A method of managing the operation of a lithium-ion battery cell and detecting an impending failure using a battery management system as described above is also disclosed.

[0016] The above features and advantages and other features and advantages of the present disclosure are readily apparent from the following detailed description of the disclosed embodiments and the best mode for carrying out the disclosed embodiments when taken in conjunction with the accompanying drawings and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a circuit diagram of a multi-cell rechargeable energy storage system (RESS) according to the present invention, the system having rechargeable lithium-ion (Li-ion) battery cells connected to a battery management system (BMS), the battery management system being equipped with a sensor array microchip that uses silicon chemically sensitive field effect transistors (CS-FETs) to detect a variety of different gases exhausted by the battery cells.

[0018] Figure 2 yes Figure 1 Schematic side views of three exemplary embodiments of lithium-ion cells are shown.

[0019] Figure 3 is a graph of data showing the amount of gas outgassing as a function of time for a typical lithium-ion battery cell leading to battery cell failure.

[0020] Figure 4 According to the present disclosure Figure 1 Schematic top view of a single microchip shown, depicting multiple CS-FETs along with microheaters and temperature sensors.

[0021] Figure 5 According to the present disclosure Figure 4 A schematic cross-sectional side view of a microchip is shown, specifically depicting one of the individual CS-FETs.

[0022] Figure 6 Shows the use of Figure 1-5 The method by which a BMS manages the operation of a lithium-ion battery cell and detects impending failure is shown. DETAILED DESCRIPTION

[0023] refer to Figure 1 , a multi-battery rechargeable energy storage system (RESS) 10. The RESS 10 includes individual battery modules 12, each of which has one or more rechargeable lithium-ion battery cells 14 (e.g. Figure 2). The RESS 10 is configured to generate and store electrical energy through an electrochemical reaction that generates heat to supply electrical energy to power an electrical load. In a battery module 12 having a plurality of lithium-ion (Li-ion) battery cells 14, the target cells may be arranged in series or in parallel, i.e., connected. Then, a plurality of such modules 12 may be arranged in a battery pack as part of the RESS 10. Although four modules 12-1, 12-2, 12-3, 12-4 are shown, it is not excluded that the RESS 10 has a greater number of such battery modules. Figure 1 The generalized version of the RESS 10 shown and its lithium-ion battery cells 14 may be used to power a variety of products, such as electric vehicles and consumer electronic devices, such as smartphones and laptop computers.

[0024] Figure 2 Three exemplary embodiments of lithium-ion battery cells 14 are depicted. Each of the target embodiments of the lithium-ion battery cells 14 includes a housing configured to enclose a corresponding negative electrode or anode, a positive electrode or cathode, and an electrolyte, gasket, etc. of the battery. Specifically, Figure 2 The respective housings of the three battery cells 14 shown in include a cylindrical housing 16A, which is typically configured as a hard metal container, a bag 16B, which is configured as a relatively flexible laminate container, and a prismatic housing 16C, which is configured as a rigid parallelogram container. Each target embodiment of the housing 16 may include an exhaust port 18, such as an opening or flue configured to exhaust gases emitted by the lithium-ion battery cells 14. The battery cell 14 having the cylindrical housing 16A may have a dedicated exhaust port 18, which is configured as a vent or flue. On the other hand, the battery cell 14 having the bag 16B or the prismatic housing 16C may be unventilated. In such a pouch or prismatic battery cell, trace gases are typically detected when the seal of the housing 16 fails and the battery has begun to operate at a reduced capacity.

[0025] Continue to refer Figure 1, the RESS 10 is operably connected to a battery management system (BMS) 20. The BMS 20 is configured to regulate the operation of the RESS 10, and in particular to detect failures and impending failures of the lithium-ion battery cells 14. In other words, the BMS 20 is designed and constructed to perform early detection of failures of the lithium-ion battery pack 14 and issue relevant warnings. When experiencing high internal reaction rates, the lithium-ion battery cells 14 can generate a large amount of heat energy, which can lead to thermal runaway events and catastrophic cell failures. In general, the term "thermal runaway event" refers to an uncontrolled temperature increase in a battery system. During a thermal runaway event, the heat generated within the battery system or battery cell exceeds the heat dissipation, resulting in a further increase in temperature. Typically, a thermal runaway event can be triggered by a variety of conditions, including a short circuit within the battery, improper battery use, physical abuse, manufacturing defects, or exposure of the battery to extreme external temperatures.

[0026] It is well known that lithium-ion battery cells, such as battery cell 14, can release or vent gases, such as hydrogen (H2), carbon dioxide (CO2), carbon monoxide (CO), and ethylene (C2H4), when undergoing a thermal chain reaction prior to catastrophic battery failure. Figure 3 As shown, the amount of gas discharged from a typical lithium-ion battery cell that causes a battery cell failure is described by curve G, where the X-axis in the figure represents time and the Y-axis represents the specific amount of gas discharged from the battery cell. The increase in the amount of gas discharged described by curve G can be divided into three general categories or stages. In stage 1, the amount of discharged gas can be characterized as trace. In stage 2, the amount of discharged gas can be characterized as moderate, and is often accompanied by visible smoke. In stage 3, the amount of discharged gas can be characterized as significant or large, often accompanied by thermal runaway, battery failure, and short-lived visible fires and explosions.

[0027] Continue to refer Figure 1 , the BMS 20 includes one or more multi-gas sensor array system-on-chip (SoC) or microchip 22 (such as Figure 1 , 2 , 4 and 5). Figure 2 As shown, in any embodiment of the lithium-ion battery cell 14, each microchip 22 can be arranged near the exhaust port 18. As described above, the lithium-ion battery cell 14 can be part of an RESS 10 having multiple similar lithium-ion battery cells 14 arranged in a single battery module 12. Thus, in such an embodiment, for example, Figure 2 As shown, the BMS 20 may include a plurality of microchips 22, one microchip for each battery cell 14. Alternatively, as shown in FIG. Figure 1As shown, each microchip 22 can be arranged at a central position or inside a single battery module 12-1, 12-2, 12-3, 12-4, such as near or inside the corresponding module exhaust port 12A-1, 12A-2, 12A-3, 12A-4, to detect a plurality of different gases exhausted by the lithium-ion battery cells 14 at the module level. In other words, in such an embodiment, each microchip 22 can be arranged to detect gases exhausted by one or more lithium-ion battery cells 14 located in a particular battery module 12.

[0028] like Figure 4 and 5 As shown, the microchip 22 includes a plurality of silicon chemically sensitive field effect transistors (CS-FETs). The CS-FETs 24 are configured to functionally detect a significant amount of a plurality of chemically distinct gases exhausted by the lithium-ion battery cells 14. Each individual CS-FET 24 is configured to detect one of the gases exhausted by the lithium-ion battery cells 14. Each individual CS-FET 24 is distinguished from the other CS-FETs by a different nanomaterial catalyst element. Figure 4 Depicted as elements 24-1, 24-2, 24-3 and 24-4. Figure 4 In the cross section 5-5 shown, Figure 5 A schematic cross section of a single sensor 24-4 mounted on a microchip 22 is specifically depicted. Within a single CS-FET 24, a nanomaterial catalyst element 24-1, 24-2, 24-3 or 24-4 is responsible for interacting with the exhaust gas. Each nanomaterial catalyst element 24-1, 24-2, 24-3 and 24-4 can be composed of a metal such as platinum (for detecting C2H4 gas), palladium-platinum (for detecting CO gas), or a metal mixture such as nickel-palladium (for detecting H2 gas) and gold-copper (for detecting CO2 gas). The thickness of each nanomaterial catalyst element can be in the range of 1-10nm.

[0029] like Figure 5As shown, microchip 22 includes a silicon transistor body 22A for supporting each nano material catalyst element 24-1, 24-2, 24-3 and 24-4. As further shown, silicon transistor body 22A forms a local silicon island to support multiple source terminals 22-1 connected to the ground (one source terminal for each nano material catalyst element 24-1, 24-2, 24-3 and 24-4). Silicon transistor body 22A also supports multiple drain terminals 22-2, each drain terminal connects corresponding nano material catalyst element 24-1, 24-2, 24-3 and 24-4 to a power source via a digital or analog converter (not shown). Nano material catalyst elements 24-1, 24-2, 24-3 and 24-4 are electrically insulated from each other and are not connected to a voltage source. Each nano material catalyst 24-1, 24-2, 24-3 and 24-4 is specially configured to interact with and detect a specific gas without interference from other gases, which is a result of the specific material properties of the target catalyst.

[0030] Functionally, each CS-FET 24 embedded in the silicon transistor body 22A is similar to a silicon electronic transistor. Typically, an electronic transistor has three electrodes, a source electrode, a gate electrode, and a drain electrode. The source electrode provides charge carriers to the transistor. The drain electrode collects or discharges charge carriers or electrons. When a voltage is applied between the drain and source electrodes, charge carriers generally flow from the source electrode to the drain electrode. The role of the gate electrode is to control this flow of charge carriers, where this flow is regulated by the amount of voltage applied to the gate.

[0031] The operation of each CS-FET 24 is similar to the electronic transistor described above, except that the flow of charge carriers from the source electrode to the drain electrode is controlled by the interaction between a specific gate electrode and a specific gas, rather than applying a fixed voltage to the gate. More specifically, in each CS-FET 24, the corresponding nanomaterial catalyst 24-1, 24-2, 24-3 and 24-4 operates as a gate electrode that is not connected to a voltage source. When a specific gas chemically reacts with a specific nanomaterial catalyst, a phenomenon generally described as a "work function change" is induced in the target nanomaterial catalyst. The resulting work function change in turn changes the flow of charge carriers from the source electrode to the drain electrode, resulting in a detection event of the exhaust gas.

[0032] The interaction between the specific gas and the specific nanomaterial catalyst 24-1, 24-2, 24-3 or 24-4 results in a modulation or change in the current flowing from the corresponding source terminal to the corresponding drain terminal in the silicon transistor body 22A. The microchip 22 may further include a microheater 28 and a temperature sensor 30, each arranged at the periphery of each CS-FET 24. The microheater 28 and the temperature sensor 30 serve a dual purpose: 1) maintain a constant microchip temperature relative to the surrounding environment, and 2) minimize environmental humidity interference. The microheater 28 and the temperature sensor 30 can be composed of a metal film with a thickness in the range of 50-500nm, such as tungsten, gold-titanium or polysilicon. As Figure 4 Shown and Figure 5 As shown in cross-section 5 - 5 , the microchip 22 may include a cavity 31 configured to minimize heat loss from the microheater and overall microchip power consumption.

[0033] Likewise Figure 4 As shown, individual CS-FETs 24 can be arranged side by side in a single plane on the sensor array microchip 22. Specifically, the individual CS-FETs 24 are arranged substantially parallel to each other. Each of the plurality of nanomaterial catalysts 24-1, 24-2, 24-3, 24-4 is sensitive to one of the gases exhausted by the lithium-ion battery cell 14, i.e., is configured to detect one of the gases. Specifically, the individual nanomaterial catalysts 24-1, 24-2, 24-3, 24-4 can be configured to detect exhausted gases such as hydrogen, carbon dioxide, carbon monoxide, and ethylene in no particular order. Although four individual nanomaterial catalysts 24-1, 24-2, 24-3, 24-4 are shown, it is not excluded that fewer or more numbers (such as Figure 4 The microchip 22 is constructed with separate nanomaterial catalysts (as shown in the two additional unoccupied sensor spaces).

[0034] Continue to refer Figure 1 , the BMS 20 also includes an electronic battery monitoring unit (CMU) 32 in operable communication with the CS-FETs 24. The CMU 32 may be part of a battery controller network (not shown) configured to manage the operation of the battery module 12. Among the various communication, processing, and management functions, the CMU 32 is configured (i.e., constructed and programmed) to receive data 35 from the CS-FETs 24 indicating a detected amount or level of at least one gas exhausted by the lithium-ion battery pack 14. The data signal 35 generated by the microchip 22 may first be transmitted to an analog or digital converter (not shown) and then transmitted to the CMU 32. The signal indicative of the data 35 transmitted by each CS-FET 24 may represent Figure 3The discrete phases in the gas emission shown, namely phase 1, phase 2 and phase 3, or corresponding to specific detected quantities of specific exhaust gases. The transmission data 35 is shown as superimposed on Figure 3 , to show how the amount detected and transmitted to the CMU 32 corresponds to the three stages of increase in the amount of exhaust gas.

[0035] The microchip 22 including the CS-FET 24 may be physically wired to a particular CMU 32 (e.g. Figure 1 ), or wirelessly communicate with the CMU. To enable wireless communication, the CMU 32 may include an antenna 32-1 for receiving data 35 from the microchip 22, for which purpose each microchip may also be equipped with a respective antenna (not shown). To support the necessary management of the battery module 12, the CMU 32 particularly includes a processor and a tangible non-transitory memory including operating instructions of the BMS 20 programmed therein. The memory may be an appropriate recordable medium that participates in providing computer-readable data or process instructions. Such a recordable medium may take a variety of forms, including but not limited to non-volatile media and volatile media.

[0036] Non-volatile media for CMU 32 may include, for example, optical or magnetic disks and other permanent storage. Volatile media may include, for example, dynamic random access memory (DRAM), which may constitute main memory. Instructions programmed into CMU 32 may be transmitted via one or more transmission media, including coaxial cables, copper wires, and optical fibers, including lines comprising a system bus coupled to a computer processor, or via wireless connections. The memory of CMU 32 may also include a floppy disk, a hard disk, a tape, another magnetic medium, a CD-ROM, a DVD, another optical medium, and the like. CMU 32 may be configured or equipped with other required computer hardware, such as a high-speed clock, necessary analog-to-digital (A / D) and / or digital-to-analog (D / A) circuits, input / output circuits and devices (I / O), and appropriate signal conditioning and / or buffering circuits. Algorithms required or accessible by CMU 32 (generally represented by numeral 34) may be stored in the memory of CMU 32 and automatically executed to facilitate the operation of BMS 20. Specifically, the algorithm 34 may include an inventory mode configured to monitor the CS-FET 24 and / or interrogate the CS-FET at predetermined time intervals to verify a valid communication line with the CS-FET and the operation of the CS-FET.

[0037] The CMU 32 is also specifically configured to compare the received exhaust gas data 35 to a corresponding predetermined threshold amount 38 of a target exhaust gas. The predetermined threshold amount 38 of the target exhaust gas may be determined empirically during testing of a representative lithium-ion battery cell, such as the battery cell 14, and programmed into the CMU 32. The CMU 32 is also configured to trigger a signal 40 indicating a battery failure and predicting thermal runaway (i.e., an imminent failure of the lithium-ion battery cell 14) when the detected amount of gas exhausted by the lithium-ion battery cell exceeds the predetermined threshold amount 38 of the target exhaust gas. For each lithium-ion battery cell 14, the corresponding predetermined threshold amount 38 programmed into the CMU 32 may be 10 ppm (parts per million) of H2, 500 ppm of CO2, 10 ppm of CO, and 10 ppm of C2H4. Figure 1 In the illustrated embodiment of the BMS 20, the respective predetermined threshold amount 38 programmed into the CMU 32 may be adjusted to account for a particular number of lithium-ion battery cells 14 in a particular battery module 12. In either embodiment, the CMU 32 may trigger a signal 40 when the detected amount of at least one exhaust gas exceeds the respective threshold amount 38.

[0038] The signal 40 may be an auditory and / or visual sensory signal or alarm. For example, the signal 40 may be an auditory indicator, such as a high decibel and / or high frequency alarm. The signal 40 may also be a visual indicator, such as a malfunction indicator light (MIL), a generated digital fault code stored in the memory of the CMU 32. The digital fault code stored in the memory of the CMU 32 may be retrieved by an authorized technician or communicated to a central organization including a database, such as an IT cloud server 42 (e.g., Figure 1 As shown, the IT cloud server 42 is arranged at a location remote from the CMU 32 and communicates wirelessly with the RESS 10, such as via antenna 32-1, to enable centralized system access and management. In such an embodiment, the external IT cloud server 42 can be part of the BMS 20, which oversees a network of multi-unit rechargeable energy storage systems, such as the RESS 10, with independent CMUs, similar to the CMU 32. The necessary communications between the various CMUs and the IT cloud server 42 can be cellular, or via a wireless local area network (Wi-Fi), or via an earth-orbiting satellite (not shown), the wireless local area network being facilitated by a cloud edge residing on a cellular base station to reduce latency.

[0039] The CMU 32 may be further configured to detect when a particular lithium-ion battery cell 14 is electrically connected to, i.e., receiving a charging current from, a battery charger 44. The CMU 32 may also be configured to electrically disconnect the lithium-ion battery cell 14 from the battery charger 44 in response to a detected amount of gas exhausted by the target battery cell (represented by data 35) exceeding a predetermined threshold amount 38 of the target exhausted gas. The CMU 32 may be configured to disconnect the battery charger 44 in parallel with or in response to the triggering or setting of the signal 40. Disconnection of the battery charger 44 may be achieved via opening a switch 46 in the circuit connecting the charger to the lithium-ion battery cell 14.

[0040] The CMU 32 may be additionally configured to detect when the lithium-ion battery unit 14 is connected to an electrical load 48, such as a vehicle subsystem, such as a heating, ventilation, and air conditioning (HVAC) system or a traction motor (not shown). In particular, when used in a motor vehicle, the RESS 10 may be connected to a high voltage bus 50 (e.g., Figure 1 35 ) is connected to an electrical load 48 and a CMU 32. In such an embodiment, the CMU 32 may also be configured to disconnect the lithium-ion battery cell 14 from the electrical load 48 in response to the detected amount of gas exhausted by the lithium-ion battery cell (represented by data 35) exceeding a predetermined threshold amount 38 of the target exhausted gas. Disconnection of the electrical load 48 may be achieved by opening a switch 52 in the circuit connecting the load to the lithium-ion battery cell 14. Similar to the case of disconnecting the charger 44 described above, the CMU 32 may be configured to disconnect the electrical load 48 in parallel with or in response to the triggering or setting of the signal 40.

[0041] The BMS 20 may also include a fire suppression system 54 configured to extinguish electrical fires. The fire suppression system 54 may, for example, include a sprinkler system having a water or foam supply system that provides sufficient pressure and flow rate to a fluid distribution piping system that is connected to a separate sprinkler unit (not shown). Another example of a fire suppression system 54 may utilize strategically arranged tanks configured to automatically distribute propellant inert gas and ultrafine aerosol particles to extinguish electrolyte fires, prevent re-ignition, and reduce the risk of battery housing explosions. The CMU 32 may be configured to activate the fire suppression system 54 in response to a detected amount of gas exhausted by the lithium-ion battery cell 14 exceeding a predetermined threshold amount 38 of the target exhaust gas.

[0042] In summary, a multi-gas sensor array microchip 22 with CS-FETs 24 is used to detect gases exhausted from lithium-ion battery cells 14 to enable early warning in the event of a lithium-ion battery failure. The multi-gas sensor array microchip 22 incorporated into the BMS 20 of the present disclosure provides a significantly more sensitive and cost-effective method to detect impending lithium-ion battery cell 14 failures than existing gas sensing technologies. The disclosed method programmed into the CMU 32 can be used to provide enhanced safety of individual lithium-ion battery cells 14 and lithium-ion battery modules 12, and help prevent catastrophic failures, fires, and explosions of lithium-ion battery cells.

[0043] A method 100 for managing the operation of a lithium-ion battery cell 14 and detecting an impending failure thereof via a BMS 20 is provided. Figure 6 shown in and referenced below Figure 1-5 The method 100 begins at box 102, where at least one of a plurality of different gases exhausted by the lithium-ion battery cell 14 is detected via the CS-FET 24 disposed on the microchip 22. After box 102, the method proceeds to box 104. In box 104, the method includes receiving data 35 indicating the amount of detected gas exhausted by at least one lithium-ion battery cell 14 from the CS-FET 24 via the CMU 32. The method proceeds from box 104 to box 106, where the method includes comparing the data 35 indicating the detected amount of the exhausted gas with a corresponding predetermined threshold amount 38 of a target exhausted gas programmed into the CMU via the CMU 32. As shown in reference Figure 1-5 As described, the predetermined threshold amount 38 programmed into the CMU 32 may be selected from 10 ppm of H2, 500 ppm of CO2, 10 ppm of CO, and 10 ppm of C2H4.

[0044] After frame 106, the method proceeds to frame 108. In frame 108, the method includes triggering, via the CMU 32, a signal 40 indicating an impending failure of the lithium-ion battery cell 14 when the detected amount of a particular gas exhausted by the lithium-ion battery cell 14 represented by the data 35 exceeds a corresponding predetermined threshold amount 38 of the target exhaust gas. After frame 108, the method may proceed to frame 110. In frame 110, the method may include determining or detecting, via the CMU 32, when the lithium-ion battery cell 14 is connected to and drawing current from a battery charger 44. After determining that the lithium-ion battery cell 14 is connected to the battery charger 44, the method may proceed to frame 112. In frame 112, the method may include electrically disconnecting the lithium-ion battery cell 14 from the battery charger 44, via the CMU 32, in response to the detected amount of the exhaust gas exceeding the corresponding predetermined threshold amount 38.

[0045] Alternatively, after frame 108 or 112, the method may proceed to frame 114. In frame 114, the method may include determining or detecting, via the CMU 32, when the lithium-ion battery cell 14 is connected to the electrical load 48. After determining that the lithium-ion battery cell 14 is connected to the electrical load 48, the method may proceed to frame 116. In frame 116, the method may include electrically disconnecting the lithium-ion battery cell 14 from the electrical load 48 via the CMU 32 in response to the detected amount of exhaust gas exceeding the corresponding predetermined threshold amount 38. After any of frames 108, 112, or 116, the method may proceed to frame 118. In frame 118, the method may include activating the fire suppression system 54 via the CMU 32 in response to the detected amount of exhaust gas exceeding the corresponding predetermined threshold amount 38.

[0046] Thus, as envisioned, the method 100 is capable of continuously monitoring the lithium-ion battery cells 14 to detect an impending failure of a target lithium-ion battery cell, and further sounding an alarm if such a condition is determined. In addition, the method 100 is capable of limiting the charging and discharging of the target battery cell 14, and further activating fire suppression if such an impending failure is established. Thus, after boxes 108, 112, 116, or 118, the method may loop back to box 104 to continue monitoring the lithium-ion battery cells 14 via the BMS 20, and detecting gases exhausted by the lithium-ion battery cells 14 via the CS-FET 24. Alternatively, the method may end in box 120.

[0047] The detailed description and drawings support and describe the present disclosure, but the scope of the present disclosure is limited only by the claims. Although some best modes and other embodiments for implementing the claimed disclosure have been described in detail, there are various alternative designs and embodiments to practice the disclosure defined in the appended claims. In addition, the embodiments shown in the drawings or the features of the various embodiments mentioned in this specification are not necessarily to be understood as embodiments independent of each other. On the contrary, each feature described in an example of an embodiment can be combined with one or more other desired features from other embodiments, resulting in other embodiments not being described in words or with reference to the drawings. Therefore, such other embodiments fall within the framework of the scope of the appended claims.

Claims

1. A battery management system configured to detect an impending failure of a lithium-ion battery cell, the battery management system comprising: a sensor array microchip comprising a plurality of silicon chemical sensitive field effect transistors (CS-FETs) configured to detect a plurality of different gases exhausted by the lithium-ion battery cells, wherein each of the CS-FETs is configured to detect one of the gases exhausted by the lithium-ion battery cells; as well as A battery monitoring unit CMU is in operative communication with the sensor array microchip and is configured to: receiving data from at least one CS-FET indicative of a detected amount of gas exhausted by the lithium-ion battery cell; comparing data indicative of the detected amount of exhaust gas to a predetermined threshold amount of a target exhaust gas programmed into the CMU; as well as When the detected amount of exhaust gas exceeds the predetermined threshold amount of the target exhaust gas, a signal indicative of an impending failure of the lithium-ion battery cell is triggered.

2. The battery management system according to claim 1, wherein: The CMU is also configured to: determining when the lithium-ion battery is connected to a battery charger; and In response to the detected amount of exhaust gas exceeding a corresponding predetermined threshold amount of the target exhaust gas, the lithium-ion battery cell is electrically disconnected from the battery charger.

3. The battery management system according to claim 1, wherein: The CMU is also configured to: determining when the lithium-ion battery cell is connected to an electrical load; and In response to the detected amount of exhaust gas exceeding a corresponding predetermined threshold amount of the target exhaust gas, the lithium-ion battery cell is disconnected from the electrical load.

4. The battery management system of claim 1 , further comprising a fire suppression system configured to extinguish an electrical fire, wherein the CMU is further configured to activate the fire suppression system in response to the detected amount of exhaust gas exceeding a corresponding predetermined threshold amount of the target exhaust gas.

5. The battery management system according to claim 1, wherein: The CS-FETs are arranged side by side in a single plane on the sensor array microchip.

6. The battery management system according to claim 5, wherein: Each detected gas exhausted by the lithium-ion battery cell is selected from a list consisting of hydrogen H2, carbon dioxide CO2, carbon monoxide CO, and ethylene C2H4.

7. The battery management system according to claim 6, wherein: The predetermined threshold amount programmed into the CMU is selected from 10 ppm of H2, 500 ppm of CO2, 10 ppm of CO, and 10 ppm of C2H4.

8. The battery management system according to claim 1, wherein: The lithium-ion battery cell is part of a multi-cell rechargeable energy storage system (RESS), the RESS having a plurality of lithium-ion battery cells arranged in a single battery module, wherein the sensor array microchip is arranged within the RESS and close to the single battery module, and wherein the sensor array microchip is configured to detect a plurality of different gases exhausted by the lithium-ion battery cells at a module level.

9. The battery management system according to claim 1, wherein: The lithium-ion battery cell includes a housing having a vent configured to vent gas, and wherein the sensor array microchip is disposed proximate to the vent.

10. The battery management system according to claim 9, wherein: The housing is configured as one of a bag-shaped, prismatic housing, and a cylindrical housing.

11. The battery management system according to claim 1, wherein: The sensor array microchip also includes a micro heater and a temperature sensor; The micro heaters and temperature sensors are arranged around the periphery of the plurality of CS-FETs and are configured to maintain a constant temperature of the sensor array microchip relative to the surrounding environment and to minimize humidity disturbance of the environment.

12. The battery management system according to claim 11, wherein: The sensor array microchip further includes a cavity, wherein the cavity is configured to minimize heat loss from the microheater and power consumption of the sensor array microchip.

13. A method of managing the operation of a lithium-ion battery cell and detecting an impending failure of the lithium-ion battery cell, the method comprising: detecting a gas exhausted by the lithium-ion battery cell via at least one of a plurality of silicon chemically sensitive field effect transistors (CS-FETs) arranged on a sensor array microchip, wherein each of the plurality of CS-FETs is configured to detect one of a plurality of different gases exhausted by the lithium-ion battery cell; receiving data indicative of a detected amount of gas exhausted by the lithium-ion battery cell from the CS-FET via a battery monitoring unit (CMU) in operative communication with the CS-FET; comparing, via the CMU, data indicative of the detected amount of exhaust gas to a predetermined threshold amount of a target exhaust gas programmed into the CMU; as well as When the detected amount of exhaust gas exceeds the predetermined threshold amount of the target exhaust gas, a signal indicative of an impending failure of the lithium-ion battery cell is triggered via the CMU.

14. The method according to claim 13, further comprising: determining, via the CMU, when the lithium-ion battery cell is connected to a battery charger; as well as In response to the detected amount of exhaust gas exceeding a corresponding predetermined threshold amount of the target exhaust gas, the lithium-ion battery cell is electrically disconnected from the battery charger via the CMU.

15. The method according to claim 13, further comprising: determining, via the CMU, when the lithium-ion battery cell is connected to an electrical load; as well as In response to the detected amount of exhaust gas exceeding a corresponding predetermined threshold amount of the target exhaust gas, the lithium-ion battery unit is disconnected from the electrical load via the CMU.

16. The method of claim 13, further comprising activating a fire suppression system via the CMU in response to the detected amount of exhaust gas exceeding a corresponding predetermined threshold amount of the target exhaust gas.

17. The method according to claim 13, wherein: The CS-FETs are arranged side by side in a single plane on the sensor array microchip.

18. The method according to claim 17, wherein: Each detected gas exhausted by the lithium-ion battery cell is selected from a list consisting of hydrogen H2, carbon dioxide CO2, carbon monoxide CO, and ethylene C2H4.

19. The method according to claim 18, wherein: The predetermined threshold amount programmed into the CMU is selected from 10 ppm of H2, 500 ppm of CO2, 10 ppm of CO, and 10 ppm of C2H4.

20. The method of claim 13, wherein: The lithium-ion battery cell is part of a multi-cell rechargeable energy storage system RESS having a plurality of lithium-ion battery cells arranged in a single battery module; The sensor array microchip is arranged within the RESS and close to a single battery module; as well as Detecting at least one of a plurality of different gases exhausted by the lithium-ion battery cells includes detecting a plurality of different gases exhausted by the lithium-ion battery cells at a module level.

21. The method according to claim 13, wherein: The lithium-ion battery cell includes a housing having a vent configured to vent gas, and wherein the sensor array microchip is disposed proximate to the vent.

22. The method according to claim 21, wherein: The housing is configured as one of a bag-shaped, prismatic housing, and a cylindrical housing.

23. The method according to claim 13, wherein: The sensor array microchip also includes a micro heater and a temperature sensor; The micro heaters and temperature sensors are arranged around the periphery of the plurality of CS-FETs and are configured to maintain a constant temperature of the sensor array microchip relative to the surrounding environment and to minimize humidity disturbance of the environment.

24. The method according to claim 23, wherein: The sensor array microchip further includes a cavity, wherein the cavity is configured to minimize heat loss from the microheater and power consumption of the sensor array microchip.

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