Systems and methods for preventing fires in rechargeable batteries

Abstract

Described herein are methods and devices for protecting a battery, such devices including: circuitry between the battery and a charger or load configured to enable transmission of electricity through the device from a charger or to a load; an electric switch positioned in the circuitry between the battery and the charger or load; a sensor configured to sense a parameter related to the battery; and a processor in data communication with the sensor and switch and configured to determine that the parameter indicates potential for a fire in the battery.

Description

[0001]SYSTEMS AND METHODS FOR PREVENTING FIRES IN RECHARGEABLE BATTERIES CROSS REFERENCE TO RELATED APPLICATIONS This application claims priority from US Provisional Patent Application No. 63 / 578,205 filed on August 23, 2023, which is expressly incorporated herein by reference in its entirety. FIELD Subject matter disclosed herein relates generally to preventing fires in rechargeable batteries. BACKGROUND Rechargeable battery fires may occur due to various factors, including manufacturing defects, mechanical damage, electrical faults, and exposure to high temperatures. In a lithium-ion battery, thermal runaway (TR) may occur when a localized increase in temperature triggers a series of exothermic reactions within the battery cells. These reactions generate heat, which may further increase the temperature, leading to a cycle of escalating temperature and energy release that can ultimately result in a battery fire or explosion. SUMMARY In various exemplary embodiments there are provided systems and methods to detect and mitigate fires in rechargeable batteries. Consistent with some disclosed embodiments a device for protecting a battery includes: circuitry between the battery and a charger or load configured to enable transmission of electricity through the device from a charger or to a load; a sensor configured to sense a parameter related to the battery; and a processor in data communication with the sensor and configured to determine that the parameter indicates potential for a fire in the battery. In some embodiments, the device further includes an electric switch positioned in the circuitry between the battery and the charger or load and in communication with the processor, wherein the processor is further configured to instruct the switch to disconnect the battery from the charger or load when a potential for a fire is determined. In some embodiments, the device further includes an electric switch positioned in the circuitry between the battery and the charger or load and in communication with the processor, wherein the processor is further configured to instruct the switch to alter the charging or discharging rates between the battery and the charger or load when a potential for a fire is determined. In some embodiments, the processor is further configured to issue an alarm when a potential fire is determined. In some embodiments, the sensor is a multi-gate field effect transistor (FET) with a conducting channel having a conductivity sensitive to a gas proximal to a surface of the multi-gate FET. In some embodiments, the parameter is detection of a gas emitted by the battery. In some embodiments, the detected gas is selected from the group consisting of hydrogen, CO, CO2, methane, ethane, hydrogen fluoride, propylene carbonate, ethyl propionate, ethylene carbonate, diethyl carbonate, dimethyl carbonate, ethylene, and a combination of the above. In some embodiments, the sensor is selected from the group consisting of an ambient temperature sensor, an ambient humidity sensor, a gas sensor, and an ambient pressure sensor. In some embodiments, the sensor is selected from the group consisting of a battery temperature sensor, a battery voltage sensor, and a battery current sensor. In some embodiments, the device is integrated into the battery. In some embodiments, the device is integrated into the charger. In some embodiments, the fire is caused by thermal runaway. In some embodiments, the device further includes a connector for connecting the device to terminals of the battery and to the charger or the load. In some embodiments, the processor is a logic circuit. Consistent with some disclosed embodiments a method for protecting a battery includes: providing circuitry between the battery and a charger or load configured to enable transmission of electricity through the device from a charger or to a load; configuring a sensor to sense a parameter related to the battery; and configuring a processor in data communication with the sensor to determine that the parameter indicates a potential for a fire in the battery. In some embodiments, the method further includes providing an electric switch positioned in the circuitry between the battery and the charger or load and in communication with the processor, and configuring the processor to instruct the switch to disconnect the battery from the charger or load when the potential for a fire is determined. In some embodiments, the method further includes providing an electric switch positioned in the circuitry between the battery and the charger or load and in communication with the processor, and configuring the processor to instruct the switch to alter the charging or discharging rates between the battery and the charger or load when the potential for a fire is determined. In some embodiments, the method further includes configuring the processor to issue an alarm when the potential for a fire is determined. In some embodiments, the sensor is a multi-gate field effect transistor (FET) with a conducting channel having a conductivity sensitive to a gas proximal to a surface of the multi-gate FET. In some embodiments, the parameter is detection of a gas emitted by the battery. In some embodiments, the detected gas is selected from the group consisting of hydrogen, CO, CO2, methane, ethylene carbonate, diethyl carbonate, dimethyl carbonate, ethylene, hydrogen fluoride, ethane, propylene carbonate, ethyl propionate, and a combination of the above. In some embodiments, the sensor is selected from the group consisting of an ambient temperature sensor, an ambient humidity sensor, a gas sensor, and an ambient pressure sensor. In some embodiments, the sensor is selected from the group consisting of a battery temperature sensor, a battery voltage sensor, and a battery current sensor. In some embodiments, the circuitry, sensor, and processor are integrated into the battery. In some embodiments, the circuitry, sensor, and processor are integrated into the charger. In some embodiments, the fire is caused by thermal runaway. In some embodiments, the method further includes providing a connector for connecting the circuitry to terminals of the battery and to the charger or the load. In some embodiments, the processor is a logic circuit. This Summary is provided to introduce a selection of concepts in a simplified form that may be further described in the Detailed Description below. It may be understood that this Summary is not intended to identify key features or essential features of the disclosure, nor is it intended to be used to limit the scope of the disclosure. The details of one or more embodiments disclosed herein may be set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS Non-limiting embodiments disclosed herein are described below with reference to figures attached hereto that are listed following this paragraph. identical structures, elements or parts that appear in more than one figure are generally labeled with the same numeral in all the figures in which they appear. When similar reference numerals are shown, corresponding description(s) are not repeated, and the interested reader is referred to the previously discussed figure(s) for a description of the like element(s). The drawings and descriptions are meant to illuminate and clarify embodiments disclosed herein, but should not be considered limiting in any way. In particular, variations and modifications apparent to those skilled in the art may be considered without departing from the claimed scope. FIGS. 1A-1E show block diagrams of systems for protecting a battery in accordance with some embodiments disclosed herein; FIG. 2 shows a flowchart of process for protecting a battery in accordance with some embodiments disclosed herein. DETAILED DESCRIPTION In some embodiments, a battery protector as disclosed herein may detect and mitigate the risk of thermal runaway or other potential fire conditions by detecting the release of gases related to TR and / or by detecting a parameter related to one or more of temperature, humidity, air pressure, voltage, and current. In some embodiments, if one or more abnormal conditions are detected indicative of a fire or the potential to start a fire, the battery protector may activate measures to prevent further escalation, such as reducing charging or discharging rates or disconnecting the battery. FIGS. 1A-1E show block diagrams of systems for protecting a battery according to some embodiments disclosed herein. As shown in FIGS. 1A-1E, a system 100 for protecting a battery 140 from a fire may include a battery protector 110 electrically connected between battery 140 and a charger 130 (FIGS. 1B, 1D and 1E) or between battery 140 and a load 150 (FIG. 1C) and including electrical circuitry 122 configured to enable a flow of current between charger 130 and battery 140 and / or between battery 140 and load 150. In some embodiments, battery 140 may be rechargeable. In some embodiments, battery 140 may be a lithium-based battery. In some embodiments, battery protector 110 may be connected only to battery 140 for protecting battery 140 even with no charger 130 or load 150 connected thereto. In some embodiments, battery protector 110 may be integrated into battery 140 (FIG. 1D). In some embodiments, battery protector 110 may be integrated into charger 130 (FIG. 1E). Battery protector 110 may include electrical connectors 108 for connecting battery protector 110 to charger 130 and / or load 150. Connectors may include wires (not shown) for non- adjacent connection of, for example, battery protector 110 to charger 130 or load 150. Load 150 may include but is not limited to a stationary load such as a household or a vehicle such as a car, scooter, or bike. In some embodiments, battery protector 110 may draw power from either of battery 140 or charger 130. Battery protector may include an electric switch 120 positioned within circuitry 122. In some embodiments, switch 120 may be configured to enable or disable an electrical connection between battery 140 and a connected charger 130 or load 150. In some embodiments, switch 120 may be configured to reduce charging or discharging rates between battery 140 and a connected charger 130 or load 150. Battery protector 110 may include one or more sensors 112 that are configured to sense one or more parameters related to battery 140. Sensors 112 may include but are not limited to an ambient temperature sensor, an ambient humidity sensor, a gas sensor, an ambient pressure sensor, a battery temperature sensor, a battery voltage sensor, and / or a battery current sensor. In some embodiments, one or more of each type of sensor 112 may be provided. In some embodiments, battery protector 110 is positioned on, within or adjacent to battery 140 so that sensors 112 are able to sample gases produced by battery 140 and / or are able to sense the parameters related to battery 140 or the ambient surroundings of battery 140. In some embodiments, a gas sensor 112 may be a multi-gate field effect transistor (FET) with a conducting channel having a conductivity sensitive to a gas proximal to a surface of the multi-gate FET such as described in US patents 10054562B2 and 11112379B2, which are incorporated herein by reference in their entirety. In some embodiments, the detected gas may include but is not limited to hydrogen, CO, CO2, methane, ethane, hydrogen fluoride, propylene carbonate, ethyl propionate, ethylene carbonate, diethyl carbonate, dimethyl carbonate, ethylene, or a combination of these or other gases. Battery protector 110 may be a computing device as defined herein. Battery protector 110 and the modules and components that are included in battery protector 110 may include or may be in communication with a non-transitory computer readable medium (such as memory 116) containing instructions that when executed by at least one processor (such as processor 114) are configured to perform the functions and / or operations necessary to provide the functionality described herein. While battery protector 110 is presented herein with specific components and modules, it should be understood by one skilled in the art, that the architectural configuration of battery protector 110 as shown may be simply one possible configuration and that other configurations with more or fewer components are possible. As referred to herein, the “components” of battery protector 110 may include one or more of the modules shown in FIG.1A as being included within battery protector 110. Battery protector 110 may include a processor 114. Processor 114 may manage the operation of the components of battery protector 110 and may direct the flow of data between the components of battery protector 110. Where battery protector 110 may be said herein to provide specific functionality or perform actions, it should be understood that the functionality or actions may be performed by processor 114 that may call on other components of battery protector 110. Processor 114 may be implemented by various types of processor devices and / or processor architectures including, for example, logic circuits, minimal instruction set computers (MISC), embedded processors, communication processors, graphics processing unit (GPU), and / or soft- core processors. In some embodiments, battery protector 110 may include a communication (comms) module 118 for enabling the transmission and / or reception of data. In some embodiments, battery protector 110 may use comms module 118 to be in wired or wireless data communication with an app 124 running on a computing device (not shown). App 124 may provide a graphical user interface for monitoring and / or configuring battery protector 110. Processor 114 may be configured to monitor the parameters provided by sensors 112 and to determine whether a parameter indicates potential for a fire, a fire, or smoke in or from battery 140. Non-limiting examples of such parameters may include detection of a gas, a current that is higher that a predefined level, or a battery temperature above a predefined level. In some embodiments, upon determining that a potential for a fire or an actual fire in battery 140 exists, processor 114 may instruct switch 120 to disconnect battery 140 from charger 130 or load 150. In some embodiments, upon determining that a potential for a fire in battery 140 exists, processor 114 may instruct switch 120 to alter the charging or discharging rates between battery 140 and charger 130 or load 150. In some embodiments, upon determining that a potential for a fire in battery 140 exists, processor 114 may raise an alarm or display a message such as on app 124. FIG. 2 shows a flowchart of process numbered 200 for protecting a battery in accordance with embodiments disclosed herein. Process 200 may be implemented in system 100 as described herein. A non-transitory computer readable medium may contain instructions which, when executed by at least one processor, perform the method and operations described at each of the steps in process 200. The non-transitory computer readable medium and at least one processor may correspond to one or more of processor 114 and memory 116 as described herein, and / or other components of battery protector 110 that may be controlled by processor 114. In step 202, a battery protector 110 may monitor the parameters from sensors 112. In decision step 204, processor 114 may determine whether any of the monitored parameters indicate the potential for a fire or an actual fire in battery 140. If the parameters do not indicate a potential for a battery fire or an actual fire, step 202 is repeated and the parameters from sensors 112 are continually monitored. If the parameters indicate a potential for a battery fire or an actual fire, then, in step 206, processor 114 may instruct switch 120 to disconnect battery 140 from charger 130 or load 150 or may instruct switch to alter the charging or discharging rates between battery 140 and charger 130 or load 150. Additionally or alternatively, processor 114 may raise an alarm and / or provide a notification such as to app 124. 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. The materials, methods, and examples provided herein are illustrative only and not intended to be limiting. Implementation of methods disclosed herein may involve performing or completing certain selected tasks or steps manually, automatically, or a combination thereof. Moreover, according to actual instrumentation and equipment, several selected steps may be implemented by hardware (HW) or by software (SW) on any operating system of any firmware, or by a combination thereof. For example, as hardware, selected steps could be implemented as a chip or a circuit. As software or algorithm, selected steps could be implemented as a plurality of software instructions being executed by a computer using any suitable operating system. In any case, selected steps could be described as being performed by a data processor, such as a computing device for executing a plurality of instructions stored in memory. Disclosed embodiments include methods, systems, devices, and computer-readable media. for providing a technical solution to the challenging technical problem of battery protection, and relate to a system for battery protection with the system having at least one processor (e.g., processor, processing circuit or other processing structure described herein). For ease of discussion, example methods are described below with the understanding that aspects of the example methods apply equally to systems, devices, and computer-readable media. For example, some aspects of such methods may be implemented by a computing device or software running thereon. The computing device may include at least one processor (e.g., a CPU, GPU, DSP, FPGA, ASIC, or any circuitry for performing logical operations on input data) to perform the example methods. Other aspects of such methods may be implemented over a network (e.g., a wired network, a wireless network, or both). As another example, some aspects of such methods may be implemented as operations or program codes in a non-transitory computer-readable medium. The operations or program codes may be executed by at least one processor. Non-transitory computer readable media, as described herein, may be implemented as any combination of hardware, firmware, software, or any medium capable of storing data that is readable by any computing device with a processor for performing methods or operations represented by the stored data. In a broadest sense, the example methods are not limited to particular physical or electronic instrumentalities, but rather may be accomplished using many differing instrumentalities. Although the disclosure refers to a “computing device”, a “computer”, or “mobile device”, it should be noted that optionally any device featuring a data processor and the ability to execute one or more instructions may be described as a computing device, including but not limited to any type of personal computer (PC), a server, a distributed server, a virtual server, a cloud computing platform, a cellular telephone, an IP telephone, a smartphone, a smart watch or a PDA (personal digital assistant). Any two or more of such devices in communication with each other may form a “network” or a “computer network”. To provide for interaction with a user, the systems and techniques described here can be implemented on a computer having a display device (a LED (light-emitting diode), or OLED (organic LED), or LCD (liquid crystal display) monitor / screen) for displaying information to the user and a keyboard and a pointing device (e.g., a mouse or a trackball) by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback (e.g., visual feedback, auditory feedback, or tactile feedback); and input from the user can be received in any form, including acoustic, speech, or tactile input.t Memory may include one or more types of computer-readable storage media including, for example, transactional memory and / or long-term storage memory facilities and may function as file storage, document storage, program storage, and / or as a working memory. The latter may, for example, be in the form of a static random-access memory (SRAM), dynamic random-access memory (DRAM), read-only memory (ROM), cache or flash memory. As long-term memory, memory may, for example, include a volatile or non-volatile computer storage medium, a hard disk drive, a solid-state drive, a magnetic storage medium, a flash memory and / or other storage facility. A hardware memory facility may, for example, store a fixed information set (e.g., software code) including, but not limited to, a file, program, application, source code, object code and the like. While certain steps methods are outlined herein as being executed by a specific module and other steps by another module, this should by no means be construed limiting. While this disclosure has been described in terms of certain embodiments and generally associated methods, alterations and permutations of the embodiments and methods will be apparent to those skilled in the art. The disclosure is to be understood as not limited by the specific embodiments described herein, but only by the scope of the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A device for protecting a battery, comprising: circuitry between the battery and a charger or load configured to enable transmission of electricity through the device from a charger or to a load; a sensor configured to sense a parameter related to the battery; and a processor in data communication with the sensor and configured to determine that the parameter indicates potential for a fire in the battery.

2. The device of claim 1, further including an electric switch positioned in the circuitry between the battery and the charger or load and in communication with the processor, wherein the processor is further configured to instruct the switch to disconnect the battery from the charger or load when the potential for a fire is determined.

3. The device of claim 1, further including an electric switch positioned in the circuitry between the battery and the charger or load and in communication with the processor, wherein the processor is further configured to instruct the switch to alter the charging or discharging rates between the battery and the charger or load when the potential for a fire is determined.

4. The device of claim 1, wherein the processor is further configured to issue an alarm when the potential for a fire is determined.

5. The device of claim 1, wherein the sensor is a multi-gate field effect transistor (FET) with a conducting channel having a conductivity sensitive to a gas proximal to a surface of the multi- gate FET.

6. The device of claim 1, wherein the parameter is detection of a gas emitted by the battery.

7. The device of claim 6, wherein the detected gas is selected from the group consisting of hydrogen, CO, CO2, methane, ethylene carbonate, diethyl carbonate, dimethyl carbonate, ethylene, hydrogen fluoride, ethane, propylene carbonate, ethyl propionate, and a combination of the above.

8. The device of claim 1, wherein the sensor is selected from the group consisting of an ambient temperature sensor, an ambient humidity sensor, a gas sensor, and an ambient pressure sensor.

9. The device of claim 1, wherein the sensor is selected from the group consisting of a battery temperature sensor, a battery voltage sensor, and a battery current sensor.

10. The device of claim 1, wherein the device is integrated into the battery.

11. The device of claim 1, wherein the device is integrated into the charger.

12. The device of claim 1, wherein the fire is caused by thermal runaway.

13. The device of claim 1, further including a connector for connecting the device to terminals of the battery and to the charger or the load.

14. The device of claim 1, wherein the processor is a logic circuit.

15. A method for protecting a battery, comprising: providing circuitry between the battery and a charger or load configured to enable transmission of electricity through the device from a charger or to a load; configuring a sensor to sense a parameter related to the battery; and configuring a processor in data communication with the sensor to determine that the parameter indicates a potential for a fire in the battery.

16. The method of claim 15, further including providing an electric switch positioned in the circuitry between the battery and the charger or load and in communication with the processor,and configuring the processor to instruct the switch to disconnect the battery from the charger or load when the potential for a fire is determined.

17. The method of claim 15, further including providing an electric switch positioned in the circuitry between the battery and the charger or load and in communication with the processor, and configuring the processor to instruct the switch to alter the charging or discharging rates between the battery and the charger or load when the potential for a fire is determined.

18. The method of claim 15, further including configuring the processor to issue an alarm when the potential for a fire is determined.

19. The method of claim 15, wherein the sensor is a multi-gate field effect transistor (FET) with a conducting channel having a conductivity sensitive to a gas proximal to a surface of the multi-gate FET.

20. The method of claim 15, wherein the parameter is detection of a gas emitted by the battery.

21. The method of claim 20, wherein the detected gas is selected from the group consisting of hydrogen, CO, CO2, methane, ethylene carbonate, diethyl carbonate, dimethyl carbonate, ethylene, hydrogen fluoride, ethane, propylene carbonate, ethyl propionate, and a combination of the above.

22. The method of claim 15, wherein the sensor is selected from the group consisting of an ambient temperature sensor, an ambient humidity sensor, a gas sensor, and an ambient pressure sensor.

23. The method of claim 15, wherein the sensor is selected from the group consisting of a battery temperature sensor, a battery voltage sensor, and a battery current sensor.

24. The method of claim 15, wherein the circuitry, sensor, and processor are integrated into the battery.

25. The method of claim 15, wherein the circuitry, sensor, and processor are integrated into the charger.

26. The method of claim 15, wherein the fire is caused by thermal runaway.

27. The method of claim 15, further including providing a connector for connecting the circuitry to terminals of the battery and to the charger or the load.

28. The method of claim 15, wherein the processor is a logic circuit.

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