Smart housing for battery in consumer electronic device

Abstract

The invention relates to a smart housing for a battery in consumer electronics. More specifically, a battery is disclosed that includes a housing, a battery management unit (BMU), a conductive trace including conductive particles disposed on a surface of the housing and electrically coupled with the BMU to form a closed loop electrical path. The BMU is configured to detect a resistance in the closed-loop electrical path caused by infiltration of the conductive particles, and determine an expansion condition of the battery based on the resistance.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 524,604, filed on June 30, 2023, entitled “SMART ENCLOSURES FOR BATTERIES INCONSUMER ELECTRONICS,” and U.S. Provisional Application No. 63 / 540,573, filed on September 26, 2023, entitled “SMART ENCLOSURES FOR BATTERIES IN CONSUMER ELECTRONICS,” which are hereby incorporated by reference in their entirety for all purposes. Technical Field

[0003] The present disclosure relates generally to batteries, such as secondary or rechargeable batteries (e.g., lithium-ion batteries, lithium iron phosphate batteries, lithium-ion polymer batteries, nickel-cadmium batteries, nickel-metal hydride batteries, lead-acid batteries, etc.), and more particularly to expansion detection of such batteries. Background Art

[0004] Batteries such as those described above can be used in a variety of consumer electronic device applications. Under certain operating conditions, the battery may swell over the life of the battery. Unrestrained battery expansion may adversely affect the battery and / or the load powered by the battery (e.g., consumer electronic devices).

[0005] Conventional techniques for detecting and / or mitigating swelling in batteries may significantly increase the size of the battery, reduce the volumetric energy density of the battery, increase the cost of the battery, or any combination thereof. Furthermore, in certain conventional implementations, swelling detection features may not be employed due to the constraints noted above. Therefore, it is now recognized that improved systems and methods are desirable. Summary of the invention

[0006] The following describes a summary of certain embodiments disclosed herein. It should be understood that these aspects are presented only to provide the reader with a concise summary of these specific embodiments, and these aspects are not intended to limit the scope of the present disclosure. In fact, the present disclosure may encompass a number of aspects that may not be described below.

[0007] In one embodiment, a battery includes a housing, a battery management unit (BMU), and a conductive trace including conductive particles, the conductive trace being disposed on a surface of the housing and electrically coupled to the BMU to form a closed-loop electrical path. The BMU is configured to detect resistance in the closed-loop electrical path caused by percolation of the conductive particles. In addition, the BMU is configured to determine a swelling condition of the battery based on the resistance.

[0008] In another embodiment, a battery includes: a housing, a percolation-based conductive trace including conductive particles disposed on a surface of the housing, and a battery management unit (BMU) coupled to the percolation-based conductive trace. The BMU is configured to detect resistance in the percolation-based conductive trace and determine a swelling condition of the battery based on the resistance.

[0009] In another embodiment, one or more tangible non-transitory computer readable media store thereon instructions that, when executed by one or more processors, are configured to cause the one or more processors to perform various functions. The functions include detecting resistance in a closed-loop electrical path caused by percolation of conductive particles disposed on a surface of a battery. The functions also include determining a swelling condition of the battery based on the resistance.

[0010] With respect to various aspects of the present disclosure, there may be various improvements to the above-mentioned features. Other features may also be incorporated in these various aspects. These improvements and additional features may exist individually or in any combination. For example, the various features discussed below with respect to one or more of the illustrated embodiments may be incorporated into any of the above-mentioned aspects of the present disclosure individually or in any combination. The brief summary presented above is intended only to familiarize the reader with certain aspects and contexts of the embodiments of the present disclosure, without limiting the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Various aspects of the present disclosure may be better understood upon reading the following detailed description and referring to the drawings described below, in which like reference numerals refer to like parts.

[0012] Figure 1 is a block diagram of an electronic device according to an embodiment of the present disclosure;

[0013] Figure 2 is a block diagram of a battery including a battery swelling detection assembly according to an embodiment of the present disclosure;

[0014] Figure 3 According to the embodiments of the present disclosure Figure 2 A schematic front view of a battery of , wherein the battery is in a fresh (eg, non-swollen) condition;

[0015] Figure 4 According to the embodiments of the present disclosure Figure 2 A schematic front view of a battery of , wherein the battery is in a swollen condition;

[0016] Figure 5 is a reflection of the embodiments according to the present disclosure Figure 3 The fresh (ie, unswollen) condition of the battery Figure 2A schematic diagram of conductive traces of a battery expansion detection assembly;

[0017] Figure 6 is a reflection of the embodiments according to the present disclosure Figure 4 The swelling of the battery Figure 2 A schematic diagram of conductive traces of a battery expansion detection assembly;

[0018] Figure 7 is a diagram showing an embodiment according to the present disclosure Figure 2 The expansion of the battery Figure 2 a graph of a relationship (e.g., a correlation) between resistances in conductive traces of a battery expansion detection assembly of a battery;

[0019] Figure 8 According to the embodiments of the present disclosure Figure 2 An exploded perspective view of a portion of a battery including various features of a battery expansion detection assembly (e.g., conductive traces formed by conductive particles, a battery management unit or BMU, etc.);

[0020] Fig. 9 According to the embodiments of the present disclosure Figure 2 A front view of a battery, wherein the battery expansion detection assembly includes a conductive trace formed of conductive particles and having an L shape;

[0021] Fig.10 According to the embodiments of the present disclosure Figure 2 A front view of a battery, wherein the battery expansion detection assembly includes a conductive particle formed and having Fig. 9 The conductive traces of different shapes are shown in the L shape;

[0022] Fig.11 According to the embodiments of the present disclosure, the Figure 1 A table of various materials in a conductive trace (eg, formed of conductive particles) of a battery expansion detection assembly of a battery; and

[0023] Fig.12 The present invention is a diagram showing a method of detecting a battery expansion through a battery expansion detection assembly according to an embodiment of the present invention. Figure 2 A process flow chart of a method for detecting a swelling condition of a battery. DETAILED DESCRIPTION

[0024] When introducing the elements of various embodiments of the present disclosure, the articles "one", "an" and "the" are intended to mean one or more elements present in the elements. The terms "include", "comprise" and "have" are intended to be inclusive, and mean that there may be additional elements other than the listed elements. In addition, it should be understood that the reference to "one embodiment" or "embodiment" of the present disclosure is not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the features. In addition, specific features, structures or characteristics can be combined in any appropriate manner in one or more embodiments. The use of the terms "roughly", "close to", "about", "close to" and / or "substantially" should be understood to mean including close to a target (e.g., design, value and amount), such as within the limits of any suitable or conceivable error (e.g., within 0.1% of a target, within 1% of a target, within 5% of a target, within 10% of a target, within 25% of a target, etc.). Furthermore, it should be understood that any exact values, numbers, measurements, etc. provided herein should be construed to include approximations of the exact values, numbers, measurements, etc. (eg, within a tolerance of appropriate or conceivable errors).

[0025] The present disclosure relates to batteries, such as secondary or rechargeable batteries (e.g., lithium-ion batteries, lithium iron phosphate batteries, lithium-ion polymer batteries, nickel-cadmium batteries, nickel-metal hydride batteries, lead-acid batteries, etc.) and / or other types of batteries employed, for example, in consumer electronic devices. More specifically, the present disclosure relates to techniques for detecting swelling conditions of such batteries.

[0026] For example, a battery may include a housing, various component parts (e.g., electrodes, separators, electrolytes) disposed within the housing, and a battery management unit (BMU). A BMU (sometimes referred to as a battery management system (BMS)) may include various component parts (e.g., processing circuits, memory circuits, sensors, etc.) configured to monitor operational aspects of the battery and prevent the battery from operating outside normal conditions (e.g., normal voltage, temperature, current, etc.).

[0027] According to the present disclosure, a conductive trace formed by conductive particles may be disposed in or on a surface of a housing and electrically coupled to a BMU to form a closed-loop electrical path. The BMU may be configured to apply (e.g., provide) a current to the closed-loop electrical path and detect a change in resistance in the closed-loop electrical path caused by infiltration of the conductive particles. For example, in an unexpanded condition of the battery, a first resistance in the closed-loop electrical path may be detected by the BMU, wherein the first resistance indicates an unexpanded condition. When the battery expands, infiltration of the conductive particles of the closed-loop electrical path may result in an interruption of the closed-loop electrical path. For example, infiltration of the conductive particles may result in a decrease in the density of the conductive particles and / or an increase in the distance between the conductive particles along the closed-loop electrical path, which may be caused by movement of the conductive particles with the expanded surface of the housing of the battery.

[0028] The above-described consequences of battery swelling may result in a change (e.g., an increase) in resistance in the closed-loop electrical path. In the event that the battery is in a swelling condition, the BMU may detect a second resistance in the closed-loop electrical path, wherein the second resistance is greater than the first resistance, thereby indicating a swelling condition of the battery. In some embodiments, the BMU may compare the second resistance to a resistance threshold, and determine the swelling condition of the battery based on the second resistance exceeding the resistance threshold. Additionally or alternatively, the BMU may compare the resistance difference between the first resistance and the second resistance to a resistance difference threshold, and determine the swelling condition of the battery based on the resistance difference exceeding the resistance difference threshold.

[0029] The above features can improve the safety of operating the battery relative to conventional embodiments that do not include expansion detection, improve (e.g., reduce) the size of the battery relative to conventional embodiments that employ other expansion detection techniques, improve (e.g., reduce) the cost of monitoring battery expansion relative to conventional embodiments that employ other expansion detection techniques, and / or enable expansion detection without a sensor element portion external to the battery (i.e., the sensing element portion is not independent), as well as other technical benefits.

[0030] Now continue to refer to the accompanying drawings, Figure 1 1 is a block diagram of an electronic device 10 according to an embodiment of the present disclosure. The electronic device 10 may include, among other things, one or more processors 12 (collectively referred to herein as a single processor for convenience, which may be implemented in any suitable form of processing circuitry), a memory 14, a non-volatile storage device 16, a display 18, an input structure 22, an input / output (I / O) interface 24, a network interface 26, and a power supply 29. Figure 1 The various functional blocks shown may include hardware elements (including circuits), software elements (including machine executable instructions), or a combination of hardware and software elements (which may be referred to as logic). Processor 12, memory 14, non-volatile storage device 16, display 18, input structure 22, input / output (I / O) interface 24, network interface 26, and / or power supply 29 may each be directly or indirectly communicatively coupled to each other (e.g., through or via another component, a communication bus, a network) to transmit and / or receive signals between each other. It should be noted that Figure 1 This is merely one example of a particular implementation and is intended to illustrate the types of components that may be present in electronic device 10 .

[0031] By way of example, electronic device 10 may include any suitable computing device, including a desktop or laptop computer, a portable electronic or handheld electronic device (such as a wireless electronic device or a smart phone), a tablet computer, a wearable electronic device, and other similar devices. In additional or alternative embodiments, electronic device 10 may include an access point, such as a base station, a router (e.g., a wireless or Wi-Fi router), a hub, a switch, etc. It should be noted that Figure 1 The processor 12 and other related items in the embodiment may be embodied in whole or in part as software, hardware, or both. Figure 1 Other related items in the electronic device 10 may be single independent processing modules, or may be fully or partially integrated into any of the other elements in the electronic device 10. The processor 12 may be implemented using a combination of a general-purpose microprocessor, a microcontroller, a digital signal processor (DSP), a field programmable gate array (FPGA), a programmable logic device (PLD), a controller, a state machine, a gated logic, a discrete hardware component, a dedicated hardware finite state machine, or any other suitable entity that can perform calculations or other manipulations of information. The processor 12 may include one or more application processors, one or more baseband processors, or both, and perform various functions described herein.

[0032] exist Figure 1 In the electronic device 10, the processor 12 may be operably coupled to the memory 14 and the non-volatile storage device 16 to execute various algorithms. Such programs or instructions executed by the processor 12 may be stored in any suitable article including one or more tangible computer-readable media. The tangible computer-readable medium may include the memory 14 and / or the non-volatile storage device 16, individually or collectively, to store instructions or routines. The memory 14 and the non-volatile storage device 16 may include any suitable article for storing data and executable instructions, such as random access memory, read-only memory, rewritable flash memory, hard drive, and optical disk. In addition, the program (e.g., operating system) encoded on such a computer program product may also include instructions that can be executed by the processor 12 to enable the electronic device 10 to provide various functions.

[0033] In some embodiments, display 18 can facilitate a user viewing images generated on electronic device 10. In some embodiments, display 18 can include a touch screen that can facilitate a user interacting with a user interface of electronic device 10. In addition, it should be understood that in some embodiments, display 18 can include one or more liquid crystal displays (LCDs), light-emitting diode (LED) displays, organic light-emitting diode (OLED) displays, active-matrix organic light-emitting diode (AMOLED) displays, or some combination of these and / or other display technologies.

[0034] The input structures 22 of the electronic device 10 may enable a user to interact with the electronic device 10 (e.g., pressing a button to increase or decrease the volume level). As with the network interface 26, the I / O interface 24 may enable the electronic device 10 to interact with a variety of other electronic devices. In some embodiments, the I / O interface 24 may include an I / O port for a hardwired connection to charge and / or manipulate content using a standard connector and protocol (such as a Lightning connector, a universal serial bus (USB), or other similar connectors and protocols). The network interface 26 may include, for example, one or more interfaces for a personal area network (PAN), such as an ultra-wideband (UWB) or Network; Local Area Network (LAN) or Wireless Local Area Network (WLAN), such as one of the IEEE 802.11x family of protocols (e.g. ) networks; and / or wide area networks (WANs), such as any standards associated with the Third Generation Partnership Project (3GPP), including, for example, 3rd generation (3G) cellular networks, Universal Mobile Telecommunications System (UMTS), 4th generation (4G) cellular networks, Long Term Evolution (LET), and / or Wide Area Networks (WANs). Cellular network, Long Term Evolution Licensed Assisted Access (LTE-LAA) cellular network, 5th generation (5G) cellular network and / or new radio (NR) cellular network, 6th generation (6G) or super 6G cellular network, satellite network, non-terrestrial network, etc. In particular, the network interface 26 may include, for example, one or more interfaces for using a cellular communication standard of the 5G specification including a millimeter wave (mmWave) frequency range (e.g., 24.25-300 gigahertz (GHz)) that defines and / or implements a frequency range for wireless communication. The network interface 26 of the electronic device 10 may allow communication through the aforementioned networks (e.g., 5G, Wi-Fi, LTE-LAA, etc.).

[0035] The network interface 26 may also include, for example, one or more interfaces for: a broadband fixed wireless access network (eg, ), mobile broadband wireless network (mobile ), asynchronous digital subscriber line (e.g., ADSL, VDSL), digital video terrestrial broadcasting Network and its extension DVB handheld devices Networks, ultra-wideband (UWB) networks, alternating current (AC) power lines, etc.

[0036] The power source 29 of the electronic device 10 may include any suitable power source, such as a rechargeable lithium polymer (Li-poly) battery and / or an alternating current (AC) power converter. According to an embodiment of the present disclosure, the battery of the power source 29 may include, for example, a battery swelling detection component configured to detect when the battery is in a swelling condition. The battery, the battery swelling detection component, and related features are described in detail below.

[0037] Figure 2 is a block diagram of one embodiment of a battery 30 (eg, a battery cell) including a battery swelling detection assembly 32. The battery 30 may correspond to, for example Figure 1 The power source 29 of the electronic device 10. However, it should be understood that the battery 30 can be used in other contexts (e.g., contexts other than consumer electronics, such as electric vehicles).

[0038] According to the present disclosure, the battery 30 includes a housing 34 (e.g., a casing, a bag, etc.) configured to house various component parts of the battery 30, such as a battery expansion detection assembly 32 (or a portion thereof), a terminal 35 (or a portion thereof), and an electrode assembly 38. In some embodiments, a portion of the terminal 35 (or "tab") protrudes from an opening in the housing 34 so that the portion is exposed for coupling to a load. The electrode assembly 38 includes electrodes 40 (such as one or more anodes and one or more cathodes), one or more separators 42, and an electrolyte 44.

[0039] In the illustrated embodiment, the battery expansion detection assembly 32 includes a conductive trace 46 formed, for example, by various conductive particles disposed on a surface (eg, an inner surface or an outer surface) of the housing 34. Fig.11 Exemplary materials corresponding to the conductive traces 46 (e.g., having conductive particles) are described in detail. A battery management unit (BMU) 48 may also be part of the battery expansion detection assembly 32, but it should be understood that the BMU 48 may perform other functions, such as monitoring other operating aspects of the battery 30 and protecting the battery 30 from operating outside normal conditions (e.g., normal voltage, temperature, current, etc.). For example, the BMU 48 includes a processing circuit 50, a memory circuit 52 having instructions stored thereon that can be executed by the processing circuit 50 to perform various functions, and a communication circuit 54 configured to enable the BMU 48 to interact with various component parts of the battery 30 and / or a load powered by the battery 30. Depending on the embodiment, the BMU 48 may be disposed inside the housing 34, outside the housing 34 (e.g., on an outer surface of the housing 34), or partially inside the housing 34 and partially outside the housing 34.

[0040] The conductive trace 46 including the conductive particles as described above is electrically coupled to the BMU 48 to form a closed-loop electrical path. In some embodiments, the BMU 48 applies (e.g., provides) current to the closed-loop electrical path and / or detects resistance in the closed-loop electrical path. When the battery 30 is in a fresh (e.g., unswollen) condition, the density of the conductive particles of the conductive trace 46 is relatively large, while the spacing between adjacent conductive particles of the conductive trace 46 is relatively small. When the battery 30 is in a swollen condition, the density of the conductive particles of the conductive trace 46 decreases as the spacing between adjacent conductive particles increases.

[0041] The above phenomenon may be referred to by the present disclosure as "percolation" of conductive particles of the conductive trace 46 (e.g., percolation-based conductive trace 46). Such percolation (which results in a decrease in the density of the conductive particles and an increase in the spacing between adjacent conductive particles, as described above) results in an increase in resistance in the conductive trace 46. The BMU 48 may identify a swelling condition of the battery 30 in response to detecting or otherwise determining an increase in resistance in the conductive trace 46. For example, the BMU 48 may determine that the resistance in the conductive trace 46 is greater than a threshold resistance. Additionally or alternatively, the BMU 48 may determine that a change in resistance (e.g., a difference between a first resistance when the battery 30 is in a fresh condition and a second resistance when the battery 30 is in a swollen condition) exceeds a threshold change (e.g., a threshold resistance difference). In this manner, in certain embodiments, smaller swellings that are typically associated with normal operation of the battery 30 may be ignored, while abnormal or undesirable amounts of swelling (e.g., greater than a threshold amount) may be identified.

[0042] In some embodiments, the BMU 48 performs an action (e.g., a control action) in response to identifying a swelling condition of the battery 30. For example, the BMU 48 may transmit an alarm, such as transmitting the alarm to an external device, displaying an alarm on a display of the device (e.g., Figure 1 The present invention may further include displaying an alarm on a display 18 of a device 10 or other load powered by a battery 30, reducing the power supplied by the battery 30, disconnecting the battery 30 from the device or other load, disconnecting the battery 30 from a charging source, etc. These and other aspects of the present disclosure are described in detail below with reference to other drawings.

[0043] Figure 3 yes Figure 2 Schematic front view of one embodiment of a battery 30, wherein the battery 30 is in a fresh (e.g., non-swollen) condition. Figure 4 yes Figure 2 A schematic front view of one embodiment of a battery 30 of FIG. 1 , wherein the battery 30 is in a swollen condition. Figure 3 and Figure 4 In the embodiment, the conductive trace 46 of the battery expansion detection assembly 32 is formed by a plurality of conductive particles 56 disposed on a surface 55 (eg, an inner surface or an outer surface) of the housing 34 of the battery 30. Figure 3 When the battery 30 is shown in a fresh (eg, unswollen) condition, the conductive particles 56 are Figure 4 The cells 30 are more densely packed when they are in the expanded state. Figure 3 In, with Figure 4 Compared to the conductive particles 56, the conductive particles 56 are more densely arranged and have smaller spacing between them. In fact, when the battery 30 (and thus the surface 55 of the housing 34) expands, the conductive particles 56 move with the movement of the surface 55. Fig.11Exemplary materials corresponding to conductive traces 46 (eg, with conductive particles 56) are described in detail.

[0044] like Figure 3 and Figure 4 As shown, the BMU 48 of the battery expansion detection assembly 32 is electrically coupled to the conductive trace 46 and measures or otherwise determines the resistance in the conductive trace 46. Figure 3 In , BMU 48 determines that the resistance in conductive trace 46 is R0, and in Figure 3 In the example, BMU 48 determines that the resistance in conductive trace 46 is R s Generally speaking, R s is usually greater than R0, which indicates a swelling condition of the battery 30. For example, Figure 5 yes Figure 2 A schematic diagram of an embodiment of a conductive trace 46 (eg, including conductive particles 56) of a battery expansion detection assembly 32, which reflects Figure 3 fresh (e.g., unswollen) condition of the battery 30 in Figure 6 yes Figure 2 A schematic diagram of an embodiment of a conductive trace 46 (eg, including conductive particles 56) of a battery expansion detection assembly 32, which reflects Figure 4 The expansion condition of the battery 30 in FIG. As shown in the figure, Figure 5 The spacing 60 between adjacent conductive particles 56 is less than Figure 6 The spacing 62 between adjacent conductive particles 56. That is, Figure 5 The density of the conductive particles 56 in the Figure 6 For at least these reasons, R s Greater than R0.

[0045] Figure 7 It is shown Figure 2 The expansion amount of the battery 30 (ie, corresponding to the X-axis 72) and Figure 2 Graph 70 of the relationship (e.g., correlation) between the resistance in the conductive trace 46 of the battery expansion detection assembly 32 of the battery 30 (i.e., corresponding to the Y-axis 74). As described above, the resistance 74 increases as the amount of expansion 72 increases. In the graph shown, the relationship between the resistance 74 and the amount of expansion 72 is linear. However, it should be understood that in certain embodiments the relationship may be non-linear. Further, in some embodiments, when the resistance exceeds the threshold resistance 76, the BMU 48 (e.g., at Figures 1 to 3 ) may identify a swelling condition of the battery 30. For example, the threshold resistance 76 may indicate a threshold swelling amount 78 that is considered abnormal, undesirable, or otherwise indicative of the battery 30 approaching or reaching an end-of-life condition.

[0046] Figure 8 yes Figure 2 30 , including various features of the battery expansion detection assembly 32 (e.g., conductive trace 46, BMU 48, etc.). As shown, the battery 30 includes a conductive trace 46 disposed on a surface 55 of the housing 34. Although the surface 55 in the illustrated embodiment is an outward-facing (e.g., exterior) surface of the housing 34, in another embodiment, the surface 55 can be an inward-facing (e.g., interior) surface of the housing 34. The thickness 79 of the conductive trace 46 (e.g., measured outward from the surface 55) can be less than 100 microns, such as 20 to 100 microns, 30 to 90 microns, 40 to 80 microns, or 50 to 70 microns. In certain other embodiments, the thickness 79 can be less than 1000 microns. In any such embodiment, the conductive trace 46 does not substantially contribute to (e.g., increase) the footprint, size, or volume of the battery 30.

[0047] The conductive trace 46 is coupled to the BMU 48 via a first connector 80 and a second connector 82. For example, a first end 84 of the conductive trace 46 is coupled to the first connector 80, and a second end 86 of the conductive trace 46 is coupled to the second connector 82. The first connector 80 and the second connector 82 are coupled to first electrical contacts 88 and second electrical contacts 90 that are integrated with the BMU 48. The BMU 48 may include or be coupled to an additional component 92 (e.g., a sensor) configured to measure or otherwise determine resistance in the conductive trace 46, as previously described.

[0048] Fig. 9 yes Figure 2 A front view of an embodiment of a battery 30 in which the battery expansion detection assembly 32 includes a conductive trace 46 having an L shape, and Fig.10 yes Figure 2 A front view of an embodiment of a battery 30, wherein the battery expansion detection assembly 32 includes a battery having a different Fig. 9 The conductive trace 46 is in the shape of an L-shape. For example, Fig.10 The shape of the conductive trace 46 in FIG. 4 may be referred to as a straight line shape. Fig. 9 The L-shape of the conductive trace 46 in corresponds to Fig. 9 The battery 30 is L-shaped, and Fig.10 The straight line shape of the conductive trace 46 in corresponds to Fig.10 The linear shape of the battery 30 in FIG. Fig. 9 and Fig.1030 is included to show an example of how the shape of the conductive trace 46 may be optimized or otherwise designed for a particular shape of the battery 30. Other shapes of the conductive trace 46 and / or battery 30 are also possible. In addition, although the shapes of the conductive trace 46 and battery 30 are Fig. 9 and Fig.10 , but such correspondence may not be included in other embodiments. For example, in another embodiment, battery 30 may include a straight shape, while conductive trace 46 may include an L shape. In some embodiments, the shape of conductive trace 46 may be designed so that the conductive particles of conductive trace 46 can percolate regardless of the direction or orientation of expansion in battery 30.

[0049] As previously described, conductive traces 46 may include conductive particles such as Figure 3 and Figure 4 Conductive particles 56 are shown. Conductive traces 46 (e.g., having Figure 3 and Figure 4 Various materials of conductive particles 56 are shown for facilitating percolation effects, detection of changing resistance in response to percolation effects, and the like. Fig.11 is included can be included Figure 1 The conductive trace 46 of the battery expansion detection assembly 32 of the battery 30 (e.g., by Figure 3 and Figure 4 A table of various materials in which the conductive particles 56 are formed is shown.

[0050] For example, a carbon-based material 95 may be used, which has a composition of graphene, graphite and / or carbon. Examples of such carbon-based materials 95 include graphene particles, carbon nanofibers, carbon nanotubes (e.g., single-walled or multi-walled), etc. Additionally or alternatively, metal or metal alloy nanoparticles 96 may be used, which have a composition of any metal compound. Examples of such metal or metal alloy nanoparticles 96 include silver, gold, platinum, nickel, chromium, etc. Additionally or alternatively, non-metallic nanoparticles 97 may be used, which have a composition of pure or doped metal oxides, carbides, nitrides, borides, sulfides, silicides and / or halides. Examples of such non-metallic nanoparticles 97 include indium tin oxide, doped titanium dioxide, doped aluminum oxide, doped zirconium oxide, silicon carbide, etc. Additionally or alternatively, a conductive polymer 98 may be used, which has a polymer material composition. Examples of such conductive polymers 98 include poly(3,4-ethylenedioxythiophene) (PEDOT), polyaniline, and the like. Other materials of the same or similar kind, composition, or material class are also possible according to the present embodiment. Generally speaking, the formulation / composition can be single-phase or multi-phase, including at least one conductive phase having an electrical conductivity (e.g., electronic and / or ionic conductivity) greater than 0.00000001 Siemens / cm (S / cm). An electrically insulating phase including an electrical conductivity (e.g., electronic and / or ionic conductivity) less than 0.00000001 S / cm can also be used as a matrix, such as polymers (e.g., polyethylene, polypropylene, polystyrene, polyimide, etc.) and ceramics (e.g., pure alumina, pure silicon oxide, etc.).

[0051] In addition, the particles of the present disclosure (e.g., conductive particles 56) may include spherical, disc-shaped, or cylindrical shapes, as previously described, wherein the aspect ratio of such particles may be less than, equal to, or greater than one. The sensing element portion currently disclosed may detect thickness changes (e.g., battery expansion), early signs of corrosion, and / or temperature changes. In addition, the sensing element portion may include any suitable pattern, wherein both ends (e.g., of the conductive trace 46) are connected to the BMS, which in some cases of the present disclosure is referred to as the BMU 48 (e.g., to form a closed-loop electrical path). In addition, the component portion may be integrated into the housing 34 by printing directly onto the inner or outer surface 55 of the housing 34 or by laminating the component portion inside the construction of the housing 34.

[0052] Fig.12 It is shown Figure 21 is a process flow diagram of one embodiment of a method 100 for detecting a swelling condition of a battery 30 via its battery swelling detection assembly 32. It should be noted that in certain embodiments, not all steps of the method 100 described below are required. In addition, it should be noted that the steps of the method 100 described below are not necessarily in chronological order, as other chronological orders are possible according to the present disclosure.

[0053] Method 100 includes applying (block 102) (e.g., providing) a current to a conductive trace formed by conductive particles disposed on a surface of a housing of a battery. For example, a BMU of the battery may be electrically coupled to the conductive trace and configured to apply (e.g., provide) the current to the conductive trace. Method 100 also includes detecting (block 104) a first resistance (R0) in the conductive trace corresponding to a fresh (e.g., unswollen) condition of the battery. That is, R0 may be detected (e.g., via the BMU) when the battery is in a fresh (e.g., unswollen) condition. Method 100 also includes detecting (block 106) a second resistance (R0) in the conductive trace corresponding to a swollen condition of the battery. s ). That is, when the battery is in a swelling condition, R s (eg, via a BMU).

[0054] Method 100 also includes R-based s or R s and R0 to identify (block 108) an expansion condition. For example, in some embodiments, the BMU may s is compared with the threshold resistance and based on R s In some embodiments, the BMU may detect an expansion condition by exceeding a threshold resistance. s The difference between R0 (e.g., change in resistance) and R0 is compared to a threshold resistance difference (e.g., threshold resistance change), and an expansion condition is detected based on the difference exceeding the threshold resistance difference. As previously described, the resistance in the conductive trace can change (e.g., increase) based on infiltration of conductive particles in the conductive trace in response to expansion of the battery.

[0055] The specific embodiments described above have been shown by way of example, and it should be understood that these embodiments may allow for various modifications and alternative forms. It should also be understood that the claims are not intended to be limited to the specific forms disclosed, but are intended to cover all modifications, equivalents, and alternatives that fall within the spirit and scope of the present disclosure.

[0056] The technology presented and claimed herein is cited and applied to specific examples of a physical and practical nature that significantly improves the art and is therefore not abstract, intangible, or purely theoretical. In addition, if any claim appended at the end of this specification contains one or more elements designated as "means for [performing] [the function] ..." or "steps for [performing] [the function] ...", it is intended that such elements should be interpreted in accordance with 35 U.S.C. 112(f). However, for any claim containing elements designated in any other manner, it is intended that such elements should not be interpreted in accordance with 35 U.S.C. 112(f).

[0057] It is understood that the use of personally identifiable information should be subject to privacy policies and practices that are generally recognized to meet or exceed industry or government requirements for maintaining user privacy. In particular, personally identifiable information data should be managed and processed to minimize the risk of unintentional or unauthorized access or use, and the nature of the authorized use should be clearly stated to users.

Claims

1. A battery, comprising: case; Battery management unit BMU; and a conductive trace including a plurality of conductive particles, the conductive trace being disposed on a surface of the housing and electrically coupled with the BMU to form a closed-loop electrical path, wherein the BMU is configured to: detecting resistance in the closed-loop electrical path caused by percolation of the plurality of conductive particles; and A swelling condition of the battery is determined based on the resistance.

2. The battery of claim 1 , wherein the BMU is configured to determine the swelling condition of the battery based on: the resistance exceeds a threshold resistance; or The change in resistance exceeds a threshold change. The battery of claim 1 , wherein the conductive traces comprise a carbon-based material. The battery according to claim 3 , wherein the carbon-based material comprises graphene, graphite or carbon.

5. The battery of claim 1, wherein the conductive trace comprises a metal or metal alloy material.

6. The battery of claim 5, wherein the metal or metal alloy material comprises silver, gold, platinum or nickel chromium.

7. The battery of claim 1, wherein the conductive traces comprise non-metallic nanoparticles.

8. The battery of claim 7, wherein the non-metallic nanoparticles comprise indium tin oxide, doped titanium dioxide, doped aluminum oxide, doped zirconium oxide, or silicon carbide.

9. The battery of claim 1, wherein the conductive traces comprise a conductive polymer.

10. The battery of claim 9, wherein the conductive polymer comprises poly(3,4-ethylenedioxythiophene) (PEDOT) or polyaniline.

11. The battery of claim 1 wherein the conductive trace has a thickness of less than 1000 microns.

12. A battery, comprising: case; and a percolation-based conductive trace comprising a plurality of conductive particles disposed on a surface of the housing; and a battery management unit (BMU) coupled to the percolation-based conductive trace and configured to: detecting resistance in the percolation-based conductive trace; as well as A swelling condition of the battery is determined based on the resistance.

13. The battery of claim 12, wherein the percolation-based conductive trace comprises a carbon-based material, a pure metal material, a metal alloy material, or any combination thereof.

14. The battery of claim 12, wherein the percolation-based conductive traces comprise non-metallic nanoparticles, non-conductive polymers, or any combination thereof.

15. The battery of claim 12, wherein the BMU is configured to determine the swelling condition of the battery based on the resistance exceeding a threshold resistance.

16. The battery of claim 12, wherein the BMU is configured as: determining whether an amount of expansion corresponding to the expansion condition exceeds a threshold amount; and A control action is performed based on the expansion amount exceeding the threshold amount, the control action including transmitting an alarm, disconnecting the battery from a load, disconnecting the battery from a charging source, or any combination thereof.

17. One or more tangible, non-transitory computer-readable media storing thereon instructions that, when executed by one or more processors, are configured to cause the one or more processors to: detecting resistance in a closed loop electrical path caused by percolation of the plurality of conductive particles on a surface of the battery; and A swelling condition of the battery is determined based on the resistance.

18. One or more tangible, non-transitory computer-readable media according to claim 17, wherein the instructions, when executed by the one or more processors, are configured to cause the one or more processors to transmit an alarm indicating the swelling condition, disconnect the battery from a load based on the swelling condition, or disconnect the battery from a charging source based on the swelling condition.

19. The one or more tangible, non-transitory computer-readable media of claim 17, wherein the instructions, when executed by the one or more processors, are configured to cause the one or more processors to determine the swelling condition of the battery based on the resistance exceeding a threshold resistance.

20. The one or more tangible, non-transitory computer-readable media of claim 17, wherein the instructions, when executed by the one or more processors, are configured to cause the one or more processors to determine whether an amount of expansion corresponding to the expansion condition exceeds a threshold amount.

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