Detecting and mitigating abnormal conditions in battery modules using thin film pressure sensors

Abstract

Some embodiments disclosed herein relate to a battery management system that utilizes a thin film pressure sensor to determine an abnormal condition associated with a battery module. Some embodiments may include receiving a pressure measurement from a thin film pressure sensor disposed between two battery cells in a battery module, and determining an abnormal condition associated with the battery module based on the pressure measurement from the thin film pressure sensor. Other embodiments are also disclosed or claimed.

Description

[0001] Introduction

[0002] This disclosure relates to detecting and mitigating abnormal conditions associated with a battery module. In particular, embodiments of this disclosure relate to a battery management system that utilizes a thin-film pressure sensor to determine abnormal conditions associated with a battery module.

[0003] Vehicles are increasingly being manufactured with propulsion systems that utilize an electric motor powered by a lithium-based battery system such as lithium-ion battery cells (LIBs) and lithium-metal battery cells (LMBs). Such a battery system can include a plurality of battery modules that can generate pressure.

[0004] After an LIB / LMB battery module is loaded onto a battery electric vehicle (BEV), there are few conventional options for monitoring the health of the battery module. For example, conventional systems typically monitor the voltage and temperature of the battery module, but these measurements typically only reflect a part of the health of the battery cells. Embodiments of this disclosure provide an improved system to detect and mitigate abnormal conditions in the battery module and can provide a timely warning when a battery cell exhibits an abnormal condition or reaches the end of its life. Summary of the Invention

[0005] In one exemplary embodiment, a system is provided that includes a battery module having a first battery cell, a second battery cell, and a thin-film pressure sensor disposed between the first battery cell and the second battery cell. The thin-film pressure sensor is adapted to measure a pressure change associated with at least one of: expansion of the first battery cell and expansion of the second battery cell. The system further includes a battery management system having a processor and a memory coupled to the processor and storing instructions that, when executed by the processor, cause the battery management system to receive a pressure measurement from the thin-film pressure sensor and determine an abnormal condition associated with the battery module based on the pressure measurement from the thin-film pressure sensor. The memory further stores instructions to cause the battery management system to generate an alert that includes an indication of the abnormal condition.

[0006] In addition to one or more of the features described herein, the first battery cell and the second battery cell are lithium-based battery cells.

[0007] In addition to one or more of the features described herein, the thin-film pressure sensor is a first thin-film pressure sensor, and wherein the battery module further includes a module frame, a third battery cell, and a second thin-film pressure sensor disposed between the third battery cell and the module frame.

[0008] In addition to one or more features described herein, the battery module includes a plurality of battery cells, the plurality of battery cells including a first battery cell, a second battery cell, and a third battery cell, and wherein at least two battery cells are disposed between a first thin film pressure sensor and a second thin film pressure sensor.

[0009] In addition to one or more features described herein, the system further includes a temperature sensor coupled to one of the battery cells from the plurality of battery cells, wherein the temperature sensor is not coupled to the first battery cell, the second battery cell, or the third battery cell.

[0010] In addition to one or more features described herein, determining an abnormal condition associated with the battery module includes determining that a pressure change measured by the thin film pressure sensor within a predetermined time period exceeds a predetermined maximum pressure level.

[0011] In addition to one or more features described herein, determining an abnormal condition associated with the battery module includes determining that an average pressure measured by the thin film pressure sensor within a predetermined time period exceeds a predetermined threshold when the battery module is in a predetermined state.

[0012] In another exemplary embodiment, a vehicle is provided with a battery module that includes a first battery cell, a second battery cell, and a thin film pressure sensor disposed between the first battery cell and the second battery cell. The thin film pressure sensor is adapted to measure a pressure change associated with at least one of: expansion of the first battery cell and expansion of the second battery cell. The vehicle further includes a battery management system that includes a processor and a memory coupled to the processor and storing instructions that, when executed by the processor, cause the battery management system to receive pressure measurements from the thin film pressure sensor and determine an abnormal condition associated with the battery module based on the pressure measurements from the thin film pressure sensor. The memory further stores instructions to cause the battery management system to generate an alert including an indication of the abnormal condition.

[0013] In addition to one or more features described herein, the first battery cell and the second battery cell are lithium-based battery cells.

[0014] In addition to one or more features described herein, the thin film pressure sensor is a first thin film pressure sensor, and wherein the battery module further includes a module frame, a third battery cell, and a second thin film pressure sensor disposed between the third battery cell and the module frame.

[0015] In addition to one or more features described herein, the battery module includes a plurality of battery cells, the plurality of battery cells including a first battery cell, a second battery cell, and a third battery cell, and wherein at least two battery cells are disposed between a first thin-film pressure sensor and a second thin-film pressure sensor.

[0016] In addition to one or more features described herein, a temperature sensor is coupled to one of the battery cells from the plurality of battery cells, wherein the temperature sensor is not coupled to the first battery cell, the second battery cell, or the third battery cell.

[0017] In addition to one or more features described herein, determining an abnormal condition associated with the battery module includes determining that a pressure change measured by the thin-film pressure sensor within a predetermined time period exceeds a predetermined maximum pressure level.

[0018] In addition to one or more features described herein, determining an abnormal condition associated with the battery module includes determining that an average pressure measured by the thin-film pressure sensor within a predetermined time period exceeds a predetermined threshold when the battery module is in a predetermined state.

[0019] In another exemplary embodiment, a battery module includes a first battery cell, a second battery cell, and a thin-film pressure sensor disposed between the first battery cell and the second battery cell. The thin-film pressure sensor is adapted to measure a pressure change associated with at least one of: expansion of the first battery cell and expansion of the second battery cell.

[0020] In addition to one or more features described herein, the first battery cell and the second battery cell are lithium-based battery cells.

[0021] In addition to one or more features described herein, the thin-film pressure sensor is a first thin-film pressure sensor, and wherein the battery module further includes a module frame, a third battery cell, and a second thin-film pressure sensor disposed between the third battery cell and the module frame.

[0022] In addition to one or more features described herein, the battery module includes a plurality of battery cells, the plurality of battery cells including a first battery cell, a second battery cell, and a third battery cell, and wherein at least two battery cells are disposed between a first thin-film pressure sensor and a second thin-film pressure sensor.

[0023] In addition to one or more features described herein, a temperature sensor is coupled to one of the battery cells from the plurality of battery cells.

[0024] In addition to one or more of the features described herein, the temperature sensor is not coupled to the first battery cell, the second battery cell, or the third battery cell.

[0025] The above features and advantages of the present disclosure, as well as other features and advantages, will be apparent from the following detailed description when considered in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In the following detailed description, other features, advantages, and details are presented by way of example only. The detailed description refers to the accompanying drawings, in which:

[0027] Figure 1 is a schematic diagram of a vehicle for use in conjunction with one or more embodiments of the present disclosure;

[0028] Figure 2 is a functional block diagram showing aspects of a battery management system according to an embodiment of the present disclosure;

[0029] Figure 3A is a perspective cross-sectional view of a battery module according to various embodiments of the present disclosure;

[0030] Figure 3B is a side view of a thin film pressure sensor 315 according to various embodiments;

[0031] Figure 3C is a graphical example showing different pressure levels measured by different parts of a thin film pressure sensor according to various embodiments;

[0032] Figure 4A is a side view of a battery module according to various embodiments;

[0033] Figure 4B is Figure 4A a side view of the battery module in

[0034] Figure 4C showing an abnormal condition associated with the battery module according to various embodiments; Figure 4A is

[0035] Figure 4D a side view of the battery module in Figure 4A showing another abnormal condition associated with the battery module according to various embodiments; and

[0036] Figure 5 is a flowchart showing a process according to various aspects of the present disclosure. DETAILED DESCRIPTION

[0037] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that in all the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0038] According to an exemplary embodiment, a battery management system for an electric motor is provided. The battery management system can determine an abnormal condition associated with a battery module based on pressure measurements from a thin film pressure sensor within the battery module, the thin film pressure sensor being adapted to measure pressure changes caused by swelling and other deformations of the battery cells of the battery module. In this way, embodiments of the present disclosure can quickly and accurately determine abnormal conditions of the battery.

[0039] Now referring Figure 1 , which shows a schematic diagram of a vehicle 100 for use in conjunction with one or more embodiments of the present disclosure. Vehicle 100 includes a charging port 102, a battery 104, and an electric motor 106. In one embodiment, vehicle 100 is a hybrid vehicle that uses both an internal combustion engine and an electric motor. In another embodiment, vehicle 100 is an electric vehicle that uses only an electric motor. In these exemplary embodiments, vehicle 100 is configured to be connected to a high voltage power source (i.e., a voltage source of at least 200 volts (V)) for charging battery 104 via charging port 102. Electric motor 106 is configured to receive electrical power from battery 104 to provide propulsion for vehicle 100.

[0040] Figure 2 is an example of a functional block diagram showing aspects of a battery management system according to an embodiment of the present disclosure. In this example, battery 104 includes a plurality of lithium-based battery modules 210, 220, 230. Each respective battery module is coupled to a respective battery monitoring unit 215, 225, 235. Battery monitoring units 215, 225, 235 are coupled to a battery management system (BMS) 250.

[0041] In Figure 2 the example depicted, three battery modules are shown by way of example, but an actual system may also include any suitable number of battery modules. In some embodiments, a single battery monitoring unit may be coupled to multiple battery modules. Additionally or alternatively, BMS 250 may also be directly coupled to some or all of battery modules 210, 220, 230 to perform the functions of battery monitoring units 215, 225, 235.

[0042] In some exemplary embodiments, BMS 250 includes at least one processor, such as a general purpose processor, a central processing unit, an application specific integrated circuit (ASIC), a digital signal processor, a field programmable gate array (FPGA), digital circuitry, analog circuitry, or a combination thereof. In some embodiments, BMS 250 includes a memory in communication with the processor to store data and instructions executable by the processor to extract measurements from battery 104 and control the characteristics of battery 104.

[0043] For example, in some embodiments, the BMS 250 manages the charging of the vehicle battery 104 (a lithium-ion battery cell in this example), and monitors and controls the battery as it discharges during operation of the vehicle 100. The BMS receives measurement signals from sensors coupled to battery modules 210, 220, 230 (in this example, via battery monitoring units 215, 225, 235). The measurement signals can include pressure measurements from one or more thin-film pressure sensors in the battery modules, as well as temperature measurements from one or more temperature sensors. The BMS 250 can also receive measurements of battery module characteristics from other types of sensors.

[0044] Figure 3A is a perspective cross-sectional view of a battery module in accordance with various embodiments of the present disclosure. In this example, the battery module 300 includes a plurality of battery cells, which include a first battery cell 305 and a second battery cell 310. The battery cells are surrounded by a module frame 320. A thin-film pressure sensor 315 is disposed between the first battery cell 305 and the second battery cell 310. A battery module in accordance with embodiments of the present disclosure can include any suitable number of battery cells and thin-film pressure sensors. For example, in Figure 3A the example shown, the battery module 300 includes a total of twelve battery cells, with three thin-film pressure sensors. In this example, the thin-film pressure sensors are disposed between every three cells.

[0045] Figure 3B is a side view of a thin-film pressure sensor 315 in accordance with various embodiments. In this example, the thin-film pressure sensor 315 is rectangular to correspond to the rectangular sides of the battery cells 305, 310, but thin-film pressure sensors operating in accordance with alternative embodiments of the present disclosure can also be of any suitable size, shape, and configuration to measure pressure variations associated with the battery cells (e.g., from swelling). Figure 3C shows a graphical example of different pressure levels (represented using different shadings) measured by different portions of the thin-film pressure sensor 315. In this manner, the thin-film pressure sensor 315 can measure the pressure levels exerted by the battery cells of the battery module on different portions of the battery cells. Identifying the specific portion(s) of the battery cell(s) that are swelling or otherwise deforming can help the battery management system of the present disclosure identify the nature and severity of abnormal conditions associated with the battery module, etc.

[0046] Figure 4Ais a side cross-sectional view of a battery module according to various embodiments. In this example, the battery module 400 includes a plurality of battery cells housed within a module frame 420, including a first battery cell 405 and a second battery cell 410. The battery module 400 also includes three temperature sensors, such as temperature sensor 430. The battery module 400 also includes three thin-film pressure sensors 415, 417, and 419. The thin-film pressure sensor 415 is disposed between the first battery cell 405 and the second battery cell 410. In this example, the plurality of battery cells are lithium-based battery cells, but embodiments of the present disclosure may also work with other types of battery cells. As shown, the thin-film pressure sensors 415 and 419 are disposed between and in contact with their respective adjacent battery cells. The thin-film pressure sensor 417 is disposed between the module frame 420 and the leftmost battery cell among the plurality of battery cells.

[0047] In Figure 4A the example shown, there are twelve battery cells, three thin-film pressure sensors, and three temperature sensors. However, alternative embodiments may include more or fewer of each of these components. For example, in some embodiments, the battery module may include four or more thin-film pressure sensors, such as two sensors (e.g., sensor 417) between the battery cells and the module frame of the battery module and two or more sensors spaced between the battery cells of the battery module. In this way, the BMS 250 can better regulate the pressure changes associated with the movement of a vehicle (e.g., when the vehicle accelerates, stops, or turns) that houses the battery module.

[0048] Embodiments of the present disclosure may also work with different types of battery cells, such as prismatic battery cells and pouch battery cells. For example, for prismatic battery cells, the size and configuration of the thin-film sensor can be designed such that it can be placed in contact with the prismatic battery cell, such that the thin-film sensor is smaller than the cross-section of the battery cell with which it is in contact. This helps to ensure that the thin-film sensor can detect any swelling or other deformation of the prismatic battery cell, while also avoiding contact with the rigid lid of the battery cell (which is less likely to deform than the body of the battery cell) and avoiding welding conflicts with the tabs extending from the battery cell.

[0049] For pouch battery cells, the thin-film sensor can similarly be sized and configured to be placed in contact with the pouch battery cell, such that the thin-film sensor is smaller than the cross-section of the battery cell with which it is in contact. This helps to avoid working on sealing non-flat tap components associated with the pouch battery cell, the sealing of which would degrade the pressure measurements collected by the thin-film sensor.

[0050] As Figure 4AAs shown, thin film pressure sensors 415, 417, and 419 are arranged alternately with three temperature sensors (e.g., temperature sensor 430). As described below, this can help BMS 250 use data from different sensors to identify specific battery cells in the battery module that are performing abnormally. In some embodiments, the BMS can receive data from the thin film pressure sensors, temperature sensors, and other sensors (e.g., voltage sensors) via a sampling chip connected to the battery module. In some embodiments, the sampling chip can be coupled to or integrated into a battery monitoring unit (e.g., Figure 2 the battery monitoring units 215, 225, 235 in

[0051] Figure 4B is Figure 4A a side cross-sectional view of the battery module in

[0052] which shows an abnormal state associated with the battery module according to various embodiments. In this example, battery cell 450 begins to expand, thereby applying an outward pressure on its adjacent battery cells. When the expansion of battery cell 450 applies pressure on its adjacent battery cells, the change in pressure can be detected by thin film pressure sensors 415 and 419. Specifically, compared to the pressure detected by sensor 419, BMS 250 can identify a relatively larger pressure detected by sensor 415 (there is only one intermediate battery cell between sensor 415 and battery cell 450), and there are three intermediate battery cells between sensor 419 and battery cell 450. BMS 250 can accordingly identify battery cell 450 as the source of the abnormal expansion condition based on the positions of sensors 415 and 419 and their relative pressure readings.

[0053] Figure 4C is Figure 4A a side cross-sectional view of the battery module in Figure 4BThe example in Figure 4B exerts an outward pressure (as indicated by the arrow). In this example, the swelling appears at the top of the battery cell 450, thereby applying a relatively high level of pressure to the top of the thin-film pressure sensors 415, 419, and a lower level of pressure to the middle and bottom of the sensors 415, 419. Thus, the BMS 250 can determine that in this example, the swelling of the battery cell 450 may be due to lithium plating failure in the battery cell rather than gas generation as in

[0054] Figure 4D is Figure 4A a side view of the battery module in

[0055] which shows another abnormal condition associated with the battery module according to various embodiments. In this example, both of the adjacent battery cells 450 and 460 are swollen, thereby applying an outward pressure on each other and their adjacent battery cells. In this example, the temperature sensor 465 is coupled to or positioned near the battery cell 460, and measures an increase in the temperature associated with the battery cell 460 when the thin-film pressure sensors 415, 419 detect an increase in pressure from the swelling of the battery cells 450 and 460. In this example, the BMS 250 can use the measurements from the temperature sensor 465 in combination with the pressure measurements from the thin-film pressure sensors 415, 419 to identify the battery cells 450 and 460 that both exhibit abnormal conditions.

[0056] In a system that relies solely on thermal sensors to monitor the battery module, the faulty battery cell typically exhibits significant swelling before the associated temperature increase can be detected, thus delaying the detection of the abnormal condition associated with the battery cell. In contrast, the embodiments of the present disclosure can detect an increase in pressure caused by the swelling or other deformation of the battery cell before detecting a subsequent increase in temperature, but can also utilize temperature sensor data (in combination with pressure sensor data) to help identify the specific battery cell(s) that exhibit abnormalities.

[0057] This short-term reading can be further periodically checked by the BMS250 to identify gradual abnormal conditions as the battery module develops, such as the failure of one or more battery cells. For example, the BMS250 can analyze the pressure level or pressure change from the same thin-film pressure sensor that measures above the aforementioned predetermined threshold level. Such periodic measurements can be made at any suitable interval, such as one second, ten seconds, thirty seconds, etc. If the second measurement value is not greater than the first measurement value, the BMS250 can continue to monitor the sensor or take no further action. However, if the second measurement value is greater than the first measurement value, the BMS250 can determine that there is a substantial possibility that the battery cell is developing into an abnormal condition (such as the risk of thermal runaway), and generate an alert to the driver of the vehicle (e.g., through the vehicle's user interface) and to other computing devices communicating with the BMS250.

[0058] In some embodiments, the BMS250 can determine whether the pressure measurements from multiple thin-film pressure sensors in the battery module indicate a gradient from one side of the battery module to the other. In this case, the BMS250 can continue to monitor the pressure measurements until a predetermined condition is met, such as when the most recent pressure level or pressure change is less than a baseline measurement. Alternatively, if the most recent pressure level or pressure change is increasing, then the BMS250 can generate an alert. The BMS250 can also determine whether to generate an alert based on other measurements associated with the battery module, such as the voltage drop reported over a tracking duration, or the pressure change that increases over at least one predetermined time period (e.g., 5 minutes).

[0059] In some embodiments, the BMS250 can simultaneously analyze voltage, temperature, and pressure sensor measurements to identify and mitigate abnormal conditions associated with the battery module. For example, the BMS 250 can generate an alert or take other mitigation actions in response to one or more of the following: a sudden voltage drop, a pressure reading exceeding a predetermined threshold, or a temperature reading exceeding a predetermined threshold.

[0060] The BMS250 can scale the mitigation response based on the severity of the identified battery cell abnormality. For example, if the temperature reading is high but not excessive (e.g., 90 °C) and the pressure reading is not abnormal, then the BMS250 can reduce the vehicle power and increase the cooling power to help mitigate the battery cell abnormality and prevent thermal runaway. In another example, if the BMS250 identifies a voltage level that exceeds a predetermined threshold, then, in combination with an excessive pressure reading, the BMS 250 can generate an alert instructing the user to park the vehicle and repair / replace the battery module to mitigate the battery cell that may be overcharging internally and generating gas.

[0061] In some embodiments, the BMS 250 can generate an alert or take other mitigation actions based on the relative position(s) of the pressure measured by the thin-film pressure sensors in the battery module. For example, as discussed above with reference to Figure 4B and Figure 4D a pressure increase with a high central gradient can be an indication of cell expansion due to gas accumulation within the cell. In such a case, the BMS 250 can generate an alert and immediately take other mitigation actions without the need to analyze data from other sensors or sources.

[0062] In some embodiments, the BMS 250 can track the pressure measurements of long-term changes generated by the thin-film pressure sensors (one or more) in the battery module. For example, in some embodiments, the BMS 250 can track the condition indicating that the battery cell or module is approaching the end of its life. For example, in some embodiments, the battery cell can expand relatively uniformly (as shown in Figure 4B and Figure 4D ), so the BMS 250 can track the average pressure level on the thin-film sensor over time. If the measured pressure value meets or exceeds a predetermined threshold, then the BMS 250 can determine that the battery cell has exceeded a safe level of expansion and issue an alert to the vehicle control system or other computer system in communication with the BMS 250, indicating that the battery module associated with the expanded battery cell needs to be appropriately repaired or replaced.

[0063] In some embodiments, for example, to avoid cell anomalies associated with lithium plating failure (such as shown in Figure 4C ), the BMS 250 can analyze the pressure measurements from the thin-film pressure sensors of the battery module, which indicate non-uniform expansion in the battery cell, such as the top expansion of the battery cell 450 in Figure 4C . In such a case, the BMS 250 can track the pressure changes on the thin-film sensor array. The BMS 250 can use any suitable index, such as standard deviation or squared deviation, for tracking. In this way, the BMS 250 can detect that the measured pressure is an indication of an anomaly where one part of the battery cell expands more than other parts of the battery cell due to lithium plating failure. In such a case, the BMS 250 can generate an alert associated with a possible lithium plating failure in the battery cell and take some mitigation measures, such as preventing rapid charging of the battery module containing the battery cell, to avoid exacerbating the lithium plating failure.

[0064] Figure 5 shows an example of a process that can be performed according to various embodiments. Figure 5The process 500 in can be performed by any suitable device or combination of devices, such as a processor of a battery management system 250 that executes computer-readable instructions stored in the memory of the battery management system 250.

[0065] In this example, process 500 includes receiving pressure measurements at 510 from a thin film pressure sensor in a battery module. The system can receive pressure measurements from any suitable number of thin film pressure sensors, which can be disposed between battery cells of the battery module and between the battery cells and the housing of the battery module.

[0066] Process 500 also includes determining, at 520, an abnormal condition associated with the battery module based on the pressure measurements from the thin film pressure sensor. The abnormal condition can be determined in combination with data from other sensors as described above, such as temperature and voltage sensors. The system can also determine a specific battery cell associated with the abnormality and the type of the abnormality based on the relative pressures measured by different portions of the thin film pressure sensor.

[0067] Process 500 also includes generating, at 530, an alert that includes an indication of the abnormal condition. The alert can be sent to any suitable computing device, such as a control system of a vehicle carrying the battery module, a user's mobile computing device, or other systems.

[0068] Some aspects explained above are summarized below by numbered examples.

[0069] Example 1. A system, comprising:

[0070] A battery module, comprising:

[0071] A first battery cell;

[0072] A second battery cell; and

[0073] A thin film pressure sensor disposed between the first battery cell and the second battery cell, the thin film pressure sensor being adapted to measure a pressure change associated with at least one of: expansion of the first battery cell and expansion of the second battery cell; and

[0074] A battery management system, comprising:

[0075] A processor; and

[0076] A memory coupled to the processor and storing instructions that, when executed by the processor, cause the battery management system to:

[0077] Receive pressure measurements from the thin film pressure sensor;

[0078] Determine an abnormal condition associated with the battery module based on pressure measurement values from the thin-film pressure sensor; and

[0079] Generate an alarm including an indication of the abnormal condition.

[0080] Example 2. The system according to Example 1, wherein the first battery cell and the second battery cell are lithium-based battery cells.

[0081] Example 3. The system according to Example 1, wherein the thin-film pressure sensor is a first thin-film pressure sensor, and wherein the battery module further comprises:

[0082] A module frame;

[0083] A third battery cell; and

[0084] A second thin-film pressure sensor disposed between the third battery cell and the module frame.

[0085] Example 4. The system according to Example 3, wherein the battery module comprises a plurality of battery cells, the plurality of battery cells including the first battery cell, the second battery cell, and the third battery cell, and wherein at least two battery cells are disposed between the first thin-film pressure sensor and the second thin-film pressure sensor.

[0086] Example 5. The system according to Example 4, further comprising a temperature sensor coupled to one of the plurality of battery cells, wherein the temperature sensor is not coupled to the first battery cell, the second battery cell, or the third battery cell.

[0087] Example 6. The system according to Example 1, wherein determining an abnormal condition associated with the battery module includes determining that a pressure change measured by the thin-film pressure sensor within a predetermined time period exceeds a predetermined maximum pressure level.

[0088] Example 7. The system according to Example 1, wherein determining an abnormal condition associated with the battery module includes determining that an average pressure measured by the thin-film pressure sensor within a predetermined time period exceeds a predetermined threshold when the battery module is in a predetermined state.

[0089] Example 8. A vehicle, comprising:

[0090] A battery module, comprising:

[0091] A first battery cell;

[0092] A second battery cell; and

[0093] A thin-film pressure sensor, the thin-film pressure sensor being disposed between the first battery cell and the second battery cell, the thin-film pressure sensor being adapted to measure a pressure change associated with at least one of: the expansion of the first battery cell and the expansion of the second battery cell; and

[0094] A battery management system, comprising:

[0095] A processor; and

[0096] A memory, the memory being coupled to the processor and storing instructions which, when executed by the processor, cause the battery management system to:

[0097] Receive a pressure measurement from the thin-film pressure sensor;

[0098] Determine an abnormal condition associated with the battery module based on the pressure measurement from the thin-film pressure sensor; and

[0099] Generate an alarm including an indication of the abnormal condition.

[0100] Example 9. The vehicle according to Example 8, wherein the first battery cell and the second battery cell are lithium-based battery cells.

[0101] Example 10. The vehicle according to Example 8, wherein the thin-film pressure sensor is a first thin-film pressure sensor, and wherein the battery module further comprises:

[0102] A module frame;

[0103] A third battery cell; and

[0104] A second thin-film pressure sensor, the second thin-film pressure sensor being disposed between the third battery cell and the module frame.

[0105] Example 11. The vehicle according to Example 10, wherein the battery module includes a plurality of battery cells, the plurality of battery cells including the first battery cell, the second battery cell, and the third battery cell, and wherein at least two battery cells are disposed between the first thin-film pressure sensor and the second thin-film pressure sensor.

[0106] Example 12. The vehicle according to Example 11, further comprising a temperature sensor, the temperature sensor being coupled to one of the battery cells from the plurality of battery cells, wherein the temperature sensor is not coupled to the first battery cell, the second battery cell, or the third battery cell.

[0107] Example 13. The vehicle according to Example 8, wherein determining an abnormal condition associated with the battery module includes determining that a change in pressure measured by the thin-film pressure sensor exceeds a predetermined maximum pressure level within a predetermined time period.

[0108] Example 14. The vehicle according to Example 8, wherein determining an abnormal condition associated with the battery module includes determining that an average pressure measured by the thin-film pressure sensor within a predetermined time period exceeds a predetermined threshold when the battery module is in a predetermined state.

[0109] Example 15. A battery module, comprising:

[0110] A first battery cell;

[0111] A second battery cell; and

[0112] A thin-film pressure sensor disposed between the first battery cell and the second battery cell, the thin-film pressure sensor being adapted to measure a pressure change associated with at least one of: expansion of the first battery cell and expansion of the second battery cell.

[0113] Example 16. The battery module according to Example 15, wherein the first battery cell and the second battery cell are lithium-based battery cells.

[0114] Example 17. The battery module according to Example 15, wherein the thin-film pressure sensor is a first thin-film pressure sensor, and wherein the battery module further comprises:

[0115] A module frame;

[0116] A third battery cell; and

[0117] A second thin-film pressure sensor disposed between the third battery cell and the module frame.

[0118] Example 18. The battery module according to Example 17, wherein the battery module includes a plurality of battery cells including the first battery cell, the second battery cell, and the third battery cell, and wherein at least two battery cells are disposed between the first thin-film pressure sensor and the second thin-film pressure sensor.

[0119] Example 19. The battery module according to Example 15, further comprising a temperature sensor coupled to one of the battery cells from the plurality of battery cells.

[0120] Example 20. The battery module according to Example 19, wherein the temperature sensor is not connected to the first battery cell, the second battery cell, or the third battery cell.

[0121] The terms "a" and "an" do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. The term "or" means "and / or" unless the context clearly dictates otherwise. References throughout the specification to "an aspect" mean that a particular element (e.g., feature, structure, step, or property) described in connection with that aspect can be included in at least one aspect described herein, and may or may not be present in other aspects. Additionally, it should be understood that the described elements can be combined in any suitable manner in the various aspects.

[0122] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements.

[0123] Unless otherwise specified herein, all test standards are the most recent standards in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0124] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0125] Although the foregoing disclosure has been described with reference to exemplary embodiments, those of ordinary skill in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from the scope of the invention. Additionally, many modifications can be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Accordingly, the disclosure is not limited to the particular embodiments disclosed, but should include all embodiments falling within its scope.

Claims

1. A system, comprising: A battery module, comprising: A first battery cell; A second battery cell; and A thin-film pressure sensor disposed between the first battery cell and the second battery cell, the thin-film pressure sensor being adapted to measure a pressure change associated with at least one of: expansion of the first battery cell and expansion of the second battery cell; and A battery management system, comprising: A processor; and A memory coupled to the processor and storing instructions that, when executed by the processor, cause the battery management system to: Receive a pressure measurement from the thin-film pressure sensor; Determine an abnormal condition associated with the battery module based on the pressure measurement from the thin-film pressure sensor; and Generate an alarm including an indication of the abnormal condition.

2. The system according to claim 1, wherein The first battery cell and the second battery cell are lithium-based battery cells.

3. The system according to claim 1, wherein The thin-film pressure sensor is a first thin-film pressure sensor, and wherein the battery module further comprises: A module frame; A third battery cell; and A second thin-film pressure sensor disposed between the third battery cell and the module frame.

4. The system according to claim 3, wherein The battery module includes a plurality of battery cells, the plurality of battery cells including the first battery cell, the second battery cell, and the third battery cell, and wherein at least two battery cells are disposed between the first thin-film pressure sensor and the second thin-film pressure sensor.

5. The system according to claim 4 further includes a temperature sensor coupled to one of the plurality of battery cells, wherein, The temperature sensor is not coupled to the first battery cell, the second battery cell, or the third battery cell.

6. The system according to claim 1, wherein Determining an abnormal condition associated with the battery module includes determining that a pressure change measured by the thin-film pressure sensor within a predetermined time period exceeds a predetermined maximum pressure level.

7. The system according to claim 1, wherein, Determining an abnormal condition associated with the battery module includes determining that an average pressure measured by the thin-film pressure sensor within a predetermined time period exceeds a predetermined threshold when the battery module is in a predetermined state.

8. A vehicle, comprising: A battery module, comprising: A first battery cell; A second battery cell; and A thin-film pressure sensor disposed between the first battery cell and the second battery cell, the thin-film pressure sensor being adapted to measure a pressure change associated with at least one of: expansion of the first battery cell and expansion of the second battery cell; and A battery management system, comprising: A processor; and A memory coupled to the processor and storing instructions that, when executed by the processor, cause the battery management system to: Receive a pressure measurement from the thin-film pressure sensor; Determine an abnormal condition associated with the battery module based on the pressure measurement from the thin-film pressure sensor; and Generate an alarm including an indication of the abnormal condition.

9. The vehicle according to claim 8, wherein, The first battery cell and the second battery cell are lithium-based battery cells.

10. A battery module, comprising: A first battery cell; A second battery cell; And A thin-film pressure sensor is disposed between the first battery cell and the second battery cell, and the thin-film pressure sensor is adapted to measure a pressure change associated with at least one of the following: the expansion of the first battery cell and the expansion of the second battery cell.

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