MEMS hall and micro heat source thermal runaway early warning sensor
By integrating MEMS Hall sensors with micro heat source sensors, the problems of large size and high power consumption of Hall sensors and insufficient gas sensor detection are solved, enabling early thermal runaway warning and rapid response within the battery module.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- WEIHAI JINGXUN CHANGTONG ELECTRONIC TECH CO LTD
- Filing Date
- 2025-05-13
- Publication Date
- 2026-05-26
AI Technical Summary
Existing Hall sensors are large in size and consume a lot of power, making them difficult to integrate into battery modules. Furthermore, traditional gas sensors cannot detect multiple thermal runaway characteristic gases simultaneously, resulting in delayed thermal runaway monitoring response and insufficient sensitivity.
A thermal runaway early warning sensor based on MEMS Hall effect and micro heat source is adopted, integrating a MEMS Hall current sensor module and a micro heat source gas sensor array module, combined with a sensor computing unit, to achieve multi-parameter fusion monitoring, including the detection of current anomalies and multiple gases.
It achieves miniaturization, low power consumption, and low failure rate of the sensor, enabling early warning of thermal runaway, rapid response and circuit cut-off to prevent the spread of thermal runaway, and is suitable for internal integration in battery modules.
Smart Images
Figure CN224287091U_ABST
Abstract
Description
Technical Field
[0001] This application belongs to the field of battery safety monitoring technology, and in particular relates to a MEMS Hall effect sensor and a micro heat source thermal runaway early warning sensor. Background Technology
[0002] With the widespread application of lithium batteries in electric vehicles, energy storage systems, and other fields, the safety issue of thermal runaway has become increasingly prominent. Traditional thermal runaway monitoring methods mainly rely on temperature sensors or single gas sensors, which suffer from problems such as response lag and insufficient sensitivity. For example, temperature monitoring requires waiting for a significant increase in the internal temperature of the battery, while characteristic gases released before thermal runaway, such as electrolyte volatiles (e.g., phosphorus pentafluoride PP5), acid and alkaline gases (e.g., HF), hydrogen, and carbon monoxide, appear much earlier. However, existing gas sensors cannot detect multiple gases simultaneously and lack miniaturization capabilities. In addition, abnormal current (e.g., a sudden increase in internal short-circuit current) is also an important precursor to thermal runaway, but traditional Hall effect sensors are bulky and consume a lot of power, making them difficult to integrate into battery modules. Therefore, there is an urgent need for a miniaturized, multi-parameter fusion sensor technology to achieve early warning of thermal runaway. Summary of the Invention
[0003] The purpose of this application is to provide a thermal runaway early warning sensor based on MEMS Hall and micro heat source to solve the technical problems of existing Hall sensors being large in size, high in power consumption, and difficult to integrate into the battery module.
[0004] To achieve the above objectives, the technical solution adopted in this application is as follows: a MEMS Hall effect sensor and micro heat source thermal runaway early warning sensor is provided, including a housing, a MEMS Hall current sensor module and a sensor computing unit are provided inside the housing, a micro heat source gas sensor array module is provided on the top of the housing, and a wire harness fixing device is provided in the middle of the housing.
[0005] In one embodiment,
[0006] The housing includes an outer shell and an inner shell, with a through hole for the detection wire harness current being disposed in the middle of the inner shell.
[0007] In one embodiment,
[0008] The MEMS Hall current sensor module includes a fixing hook on the outside of the inner shell, a magnetic core supported on the fixing hook, a MEMS Hall element inside the magnetic core, and a compensation coil outside the magnetic core.
[0009] In one embodiment,
[0010] The micro heat source gas sensor array module consists of micro heat source gas sensors, with at least one micro heat source gas sensor, and multiple micro heat source gas sensors are evenly arranged on the top of the housing.
[0011] In one embodiment,
[0012] The sensor computing unit includes a Hall current sensor computing unit and a micro heat source gas sensor computing unit located inside the housing.
[0013] In one embodiment,
[0014] A communication harness interface is provided through the middle of the housing. Multiple micro heat source gas sensors and sensor computing units are electrically connected through the harness, which extends out of the housing through the communication harness interface.
[0015] In one embodiment,
[0016] The wire harness fixing device includes a fixing bolt that passes through the outer shell and the inner shell, and a fixing plate is provided on the fixing bolt on one side of the inner shell.
[0017] In one embodiment,
[0018] The distance between the fixing plate and the inner shell is adjusted by fixing bolts.
[0019] In one embodiment,
[0020] The number of MEMS Hall elements must be at least one.
[0021] This application provides a MEMS Hall effect sensor and a micro heat source thermal runaway early warning sensor. The sensor circuit is simple, small in size and light in weight, with low power consumption, low failure rate and low manufacturing cost, and can be easily integrated into the battery module. The micro heat source gas sensor array module can detect multiple gases at the same time, with diversified functions. The sensor computing unit enables the sensor to respond quickly and have high sensitivity. No microcontroller is required. High-precision light intensity measurement, threshold triggering and early warning of thermal runaway can be achieved by using only a voltage comparator. Attached Figure Description
[0022] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0023] Figure 1 This is a three-dimensional side view of the sensor;
[0024] Figure 2 This is a cross-sectional view of the sensor;
[0025] Figure 3 Remove the housing from the bottom view of the sensor;
[0026] Figure 4This is a bottom view of the sensor.
[0027] Figure 5 This is a workflow diagram.
[0028] Explanation of symbols in the diagram:
[0029] 1. Outer shell; 2. Inner shell; 3. Current through hole for detection harness; 4. Fixing bolt; 5. Communication harness interface; 6. Micro heat source gas sensor; 7. MEMS Hall current sensor module; 71. Magnetic core; 72. MEMS Hall element; 73. Compensation coil; 74. Fixing hook; 8. Fixing pressure plate; 9. Micro heat source gas sensor calculation unit; 10. Hall current sensor calculation unit; 11. Top cover; 12. Bottom cover. Detailed Implementation
[0030] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, this application will be further described in detail. It should be understood that the specific embodiments described herein are only for explaining this application and are not intended to limit this application.
[0031] In one embodiment, a MEMS Hall effect sensor with micro-heat source thermal runaway early warning, such as... Figure 1-2 As shown, the device includes a housing, with a MEMS Hall current sensor module 7 located at the bottom inside the housing, a micro heat source gas sensor array module and a sensor computing unit located at the top of the housing, and a wire harness fixing device located in the middle of the housing.
[0032] Specifically, the housing integrates the internal components of the runaway warning sensor. The MEMS Hall current sensor module 7 detects abnormal fluctuations in the battery charging and discharging current (such as a sudden increase in current or ripple distortion caused by an internal short circuit) and generates a first-level warning signal by combining it with a preset threshold algorithm. The micro heat source gas sensor array module integrates a MEMS micro heat source gas-sensitive material unit, which optimizes the selective detection of different gases through independent temperature control (100-400℃). The sensor computing unit performs multimodal data fusion, sets the warning logic, and transmits the detection signal. The wire harness fixing device is used to fix the wire harness under test.
[0033] In one embodiment, the housing includes an outer shell 1 and an inner shell 2, with a through-hole 3 for detecting the current of the wire harness disposed in the middle of the inner shell 2; as shown Figure 3As shown, the MEMS Hall current sensor module 7 includes a fixing hook 74 disposed on the outside of the inner shell 2, a magnetic core 71 supported on the fixing hook 74, a MEMS Hall element 72 disposed inside the magnetic core 71, and a compensation coil 73 disposed outside the magnetic core 71; the micro heat source gas sensor array module is composed of micro heat source gas sensors 6; the sensor computing unit includes a Hall current sensor computing unit 10 and a micro heat source gas sensor computing unit 9 disposed on the inner wall of the outer shell 1; a communication harness interface 5 is provided through the middle of the outer shell 1; the harness fixing device includes a fixing bolt 4, which passes through the outer shell 1 and the inner shell 2, such as Figure 4 As shown, a fixing plate 8 is provided on the fixing bolt 4 on one side of the inner shell 2.
[0034] Specifically, both the outer shell 1 and the inner shell 2 are cylindrical, with a cavity between them. The outer shell 1 includes an outer body, a top cover 11, and a bottom cover 12. Multiple fixing hooks 74 can be provided and are fixedly connected to the inner shell 2 to fix the magnetic core 71. The number of MEMS Hall elements 72 is at least one, and in this embodiment, there are two. The MEMS Hall elements 72 are disposed inside the magnetic core 71 and are used for real-time current monitoring. The number of micro-heat source gas sensors 6 is at least one, and in this embodiment, there are four: a first micro-heat source gas sensor (for detecting reducing gases such as CO and H), a second micro-heat source gas sensor (for detecting acidic volatiles such as HF and PCl), a third micro-heat source gas sensor (for detecting sudden changes in O concentration), and a fourth micro-heat source gas sensor (for detecting sudden changes in the concentration of electrolyte volatile PP5). The four micro-heat source gas sensors 6 are inserted into the top cover 11 and evenly arranged. The Hall current sensor calculation unit 10 and the micro-heat source gas sensor calculation unit 9 communicate with each other. The micro heat source gas sensor computing unit 9 is fixed to the inner wall of the outer shell 1 by screws. The micro heat source gas sensor computing unit 9 integrates a temperature compensation module, and the Hall current sensor computing unit 10 integrates a DAC. The built-in microprocessor of the sensor computing unit performs time series fusion analysis on the current signal and gas concentration data. It adopts a dynamic threshold adjustment algorithm to distinguish between normal charging and discharging gas release and thermal runaway precursors: if only the current is abnormal, a low-level alarm is triggered; if the gas concentration continues to rise and is accompanied by an abnormal current, a high-level warning is immediately triggered and the battery protection system is activated. The four micro heat source gas sensors 6 are electrically connected to the sensor computing unit through a wire harness. The wire harness extends out of the outer shell 1 through the communication wire harness interface 5 and connects to the host computer for signal conversion and transmission. One end of the fixing bolt 4 is fixedly connected to the fixing plate 8. The wire harness to be tested is inserted between the fixing plate 8 and the inner shell 2 through the detection wire harness current through hole 3. The fixing bolt 4 is rotated to reduce the distance between the fixing plate 8 and the inner shell 2, and the wire harness to be tested is fixed on the inner shell 2.
[0035] The specific structure of this utility model has been described in detail above. The following description, in conjunction with... Figures 1-5The working principle of the above-mentioned MEMS Hall effect sensor and micro heat source thermal runaway early warning sensor is described as follows:
[0036] Taking an electric vehicle battery module as an example: sensors are embedded inside the battery module. The MEMS Hall current sensor module 7 is connected in series at the battery tab, and the micro heat source gas sensor array module is close to the battery pressure relief valve. When a slight internal short circuit occurs in the battery, the MEMS Hall current sensor module 7 detects abnormal current fluctuations, and at the same time, the first micro heat source gas sensor detects that the CO concentration rises from 5ppm to 20ppm. The microprocessor of the sensor computing unit determines that the dual-mode parameters are out of limit, triggers an early warning within 0.5 seconds, and the system cuts off the circuit and starts cooling to prevent the spread of thermal runaway.
[0037] This application provides a MEMS Hall effect sensor and a micro-heat source thermal runaway early warning sensor, including a housing. The housing houses a MEMS Hall current sensor module and a sensor computing unit. A micro-heat source gas sensor array module is located on the top of the housing, and a wiring harness fixing device is located in the middle of the housing. The sensor circuit is simple, small in size and light in weight, with low power consumption, low failure rate, and low manufacturing cost, and can be easily integrated into a battery module. The micro-heat source gas sensor array module can simultaneously detect multiple gases, offering diverse functions. The sensor computing unit enables fast sensor response and high sensitivity. No microcontroller is required; high-precision light intensity measurement, threshold triggering, and early warning of thermal runaway can be achieved using only a voltage comparator.
[0038] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.
[0039] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.
Claims
1. A MEMS Hall effect sensor for thermal runaway early warning based on micro heat sources, comprising a housing, characterized in that, The housing contains a MEMS Hall current sensor module and a sensor computing unit, a micro heat source gas sensor array module at the top of the housing, and a wire harness fixing device in the middle of the housing.
2. The MEMS Hall effect sensor and micro-heat source thermal runaway early warning sensor according to claim 1, characterized in that, The housing includes an outer shell and an inner shell, with a through hole for the detection wire harness current being disposed in the middle of the inner shell.
3. The MEMS Hall effect sensor and micro-heat source thermal runaway early warning sensor according to claim 2, characterized in that, The MEMS Hall current sensor module includes a fixing hook disposed on the outer side of the inner shell, a magnetic core supported on the fixing hook, a MEMS Hall element disposed inside the magnetic core, and a compensation coil disposed outside the magnetic core.
4. The MEMS Hall effect sensor and micro-heat source thermal runaway early warning sensor according to claim 2, characterized in that, The micro heat source gas sensor array module is composed of micro heat source gas sensors, and the number of micro heat source gas sensors is at least one, with multiple micro heat source gas sensors evenly arranged on the top of the housing.
5. A MEMS Hall effect sensor and micro-heat source thermal runaway early warning sensor according to claim 4, characterized in that, The sensor computing unit includes a Hall current sensor computing unit and a micro heat source gas sensor computing unit disposed inside the housing.
6. A MEMS Hall effect sensor and micro-heat source thermal runaway early warning sensor according to claim 5, characterized in that, A communication harness interface is provided through the middle of the housing. Multiple micro heat source gas sensors and sensor computing units are electrically connected through the harness, which extends out of the housing through the communication harness interface.
7. A MEMS Hall effect sensor and micro-heat source thermal runaway early warning sensor according to claim 2, characterized in that, The wire harness fixing device includes a fixing bolt that passes through the outer shell and the inner shell, and a fixing pressure plate is provided on the fixing bolt on one side of the inner shell.
8. A MEMS Hall effect sensor and micro-heat source thermal runaway early warning sensor according to claim 7, characterized in that, The distance between the fixing plate and the inner shell is adjusted by the fixing bolts.
9. A MEMS Hall effect sensor and micro-heat source thermal runaway early warning sensor according to claim 3, characterized in that, The number of MEMS Hall elements is at least one.