Detection of impending failure of lithium-ion batteries

Abstract

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

Description

Technical Field

[0001] The present invention generally relates to a system and method for detecting that a lithium-ion battery is about to be damaged.

[0002] This application claims the benefit of priority of U.S. Patent Application No. 62 / 979,322, filed on February 20, 2020, the entire specification of which is incorporated herein by reference.

Background Art

[0003] An electrical energy storage (storage) or battery system or array may include a plurality of batteries that are relatively close to each other. The plurality of batteries can be assembled into a battery stack or module, and further, a plurality of battery modules can be assembled into a battery pack. Batteries can be broadly classified into primary batteries and secondary batteries. A primary battery (also called a disposable battery) is used until it is exhausted, and when it is exhausted, it is simply replaced with a new battery. A secondary battery (more generally, a rechargeable battery) employs a specific high-energy chemistry that allows the battery to be repeatedly charged and reused, and thus has the advantages of being more economical, having a smaller environmental burden, and being easier to handle compared to disposable batteries.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Rechargeable batteries can be used to power a variety of items, such as toys, consumer electronic devices, and motorized vehicles. Due to certain chemical reactions in rechargeable batteries, such as lithium-ion batteries, and external factors, in extreme cases, internal reaction rates can reach a level that generates a significant amount of thermal energy, potentially leading to thermal events. As internal reactions within rechargeable batteries accelerate, many such batteries release gas, a potential precursor to catastrophic battery failure. The safety of rechargeable batteries is a significant concern given their widespread application in motorized vehicles, aviation, and consumer electronic devices such as smartphones and laptops. Safety is particularly concerning in the field of electric vehicles, due to the growing demand for vehicles that can be rapidly charged and have long driving ranges, which in turn increases the number of batteries used within these vehicles. [Means for solving the problem]

[0005] A battery management system configured to detect imminent failure of a lithium-ion battery includes a sensor array microchip. The microchip includes multiple silicon chemosensible field-effect transistors (CS-FETs) configured to detect several specific types of gases emitted by the lithium-ion battery. The battery management system also includes a cell monitoring unit (CMU) configured to receive from at least one of the CS-FETs data indicating the detected amount of gas emitted by the lithium-ion battery. The CMU is also configured to compare the data indicating the detected amount of emitted gas with a predetermined threshold amount of the emitted gas programmed within the CMU. The CMU is further configured to trigger a signal indicating imminent failure of the lithium-ion battery when the detected amount of emitted gas exceeds the predetermined threshold amount of the emitted gas.

[0006] The CMU may further be configured to determine whether the lithium-ion battery is connected to a charger (battery charger). In such an embodiment, the CMU may further be configured to electrically disconnect the lithium-ion battery from the charger in response to the detected amount of each of the emitted gases exceeding a predetermined threshold amount.

[0007] The CMU may also be configured to determine whether a lithium-ion battery is connected to an electrical load. The CMU may further be configured to disconnect the lithium-ion battery from the electrical load in response to the detected amount of each of the emitted gases exceeding a predetermined threshold.

[0008] The battery management system may further include a fire suppression system configured to extinguish fires caused by electrical leakage. In such an embodiment, the CMU may further be configured to activate the fire suppression system in response to the detected amount of exhaust gas exceeding a predetermined threshold amount of the exhaust gas.

[0009] CS-FETs can be arranged in a single plane on a sensor array microchip. Furthermore, each CS-FET can be configured to detect one of several types of gases emitted by a lithium-ion battery.

[0010] Each of the gases to be emitted and detected by the lithium-ion battery may be selected from a list including hydrogen (H2), carbon dioxide (CO2), carbon monoxide (CO), and ethylene (C2H4). Furthermore, predetermined threshold amounts programmed within the CMU may be selected from 10 ppm for H2, 500 ppm for CO2, 10 ppm for CO, and 10 ppm for C2H4.

[0011] The lithium-ion battery may be part of a multi-cell rechargeable energy storage system (RESS) comprising multiple lithium-ion batteries arranged within individual battery modules. In such an embodiment, the sensor array microchip may be positioned within the RESS in close proximity to the individual battery modules. Furthermore, the sensor array microchip may be configured to detect multiple types of specific gases emitted by the lithium-ion battery at the module level.

[0012] The lithium-ion battery may include a housing having an exhaust port configured to release gas. In such embodiments, the sensor array microchip may be positioned in close proximity to the exhaust port.

[0013] The housing for a lithium-ion battery can be configured as one of the following: a pouch, a prismatic casing, or a cylindrical casing.

[0014] We also disclose a method for managing the operation of lithium-ion batteries using the aforementioned battery management system, as well as a method for detecting when lithium-ion batteries are on the verge of failure.

[0015] The features and advantages of this teaching described above, as well as other features and advantages, will be readily apparent by reading the following detailed description of one or more embodiments and one or more best modes for carrying out this disclosure, with reference to the attached figures and attached claims. [Brief explanation of the drawing]

[0016] [Figure 1] A circuit diagram of a multi-cell rechargeable energy storage system (RESS) having a rechargeable lithium-ion (Li-ion) battery connected to a battery management system (BMS) equipped with a sensor array microchip, showing the detection of multiple types of specific gases emitted by the battery using silicon chemosensible field-effect transistors (CS-FETs) according to the present disclosure. [Figure 2] A schematic side view illustrating three embodiments of the lithium-ion battery shown in Figure 1. [Figure 3] A data plot showing the amount of gas released by a typical lithium-ion battery, as a function of time, until the battery is damaged. [Figure 4] Figure 1 is a schematic diagram showing the top surface of an individual microchip, illustrating multiple CS-FETs along with the microheater and temperature sensor according to this disclosure. [Figure 5] Figure 4 shows a schematic cross-section of the microchip, and more specifically, it shows one of the individual CS-FETs according to this disclosure. [Figure 6] Figures 1 to 5 illustrate how to manage the operation of lithium-ion batteries and detect imminent failure of lithium-ion batteries using the BMS shown. [Modes for carrying out the invention]

[0017] Figure 1 shows a multi-cell rechargeable energy storage system (RESS) 10. RESS 10 includes individual battery modules 12, each of which has one or more lithium-ion batteries 14 (see Figure 2). RESS 10 is configured to generate and store electrical energy using an exothermic electrochemical reaction that provides electrical energy to supply power to an electrical load. Multiple lithium-ion (Li-ion) batteries 14 are arranged within a battery module 12, i.e., connected in series or parallel. Multiple such modules 12 can be arranged within a battery pack as part of RESS 10. Four modules 12-1, 12-2, 12-3, and 12-4 are illustrated, but RESS 10 may have many more such battery modules. A typical RESS 10 with lithium-ion batteries 14 as shown in Figure 1 can be used to power a variety of products, such as electric vehicles and consumer electronic devices like smartphones and laptops.

[0018] Figure 2 shows three embodiments of the lithium-ion battery 14. Each of these embodiments of the lithium-ion battery 14 includes a housing configured to surround the battery electrolyte, (one or more) gaskets, etc., along with the respective cathodes (or anodes) and positive electrodes (or cathodes). Specifically, the housings of the three batteries 14 shown in Figure 2 include a cylindrical casing 16A configured as a generally rigid metal container, a pouch 16B configured as a container made of a relatively flexible laminated material, and a prismatic casing 16C configured as a rigid container formed in the shape of a parallelepiped. Each of these embodiments of the housing 16 may include an opening or chimney-like outlet 18 configured to discharge gases released by the lithium-ion battery 14. The battery 14 with the cylindrical casing 16A may have a dedicated outlet 18 configured as an opening or chimney for discharge. On the other hand, the battery 14 with either the pouch 16B or the prismatic casing 16C is non-permeable. In batteries with such pouch or prismatic shapes, trace amounts of gas are easily detected if there is a defect in the sealing of the housing 16 and the battery starts operating at a small capacity.

[0019] Referring again to Figure 1, the RESS 10 is operably connected to the Battery Management System (BMS) 20. The BMS 20 is configured to regulate the operation of the RESS 10, and in particular to detect malfunctions and impending failure of the lithium-ion battery 14. In other words, the BMS 20 is designed and configured to perform early detection of failure of the lithium-ion battery 14 and issue alarms (notifications) regarding such failure. When a high internal reaction rate occurs, the lithium-ion battery 14 can generate a considerable amount of thermal energy, which can lead to events where the temperature continues to rise and irreversible battery failure occurs. The phrase "event where the temperature continues to rise" generally means that the temperature in the battery system continues to rise to an uncontrollable level. When an event where the temperature continues to rise occurs, if the amount of heat generated in the battery system or within the battery exceeds the amount of heat dissipated, the temperature will rise further. Events that cause a battery to continue to rise in temperature are generally triggered by a variety of conditions, including short circuits within the battery, improper battery use, physical misuse, manufacturing defects, or exposure of the battery to extreme ambient temperatures.

[0020] Lithium batteries, such as battery 14, are known to release or emit gases such as hydrogen (H2), carbon dioxide (CO2), carbon monoxide (CO), and ethylene (C2H4) when a thermal chain reaction occurs before irreversible failure occurs. In the graph shown in Figure 3 (with time on the X-axis and the amount of a specific gas released by the battery on the Y-axis), the amount of gas released by the lithium-ion battery 14 that causes it to fail is represented by curve G. The increase in gas release shown by curve G can be divided into three typical categories or stages. In Stage 1, the amount of released gas may be perceived as a trace amount (gas). In Stage 2, the amount of released gas may be perceived as moderate and generally accompanied by visible smoke. In Stage 3, the amount of released gas may be perceived as considerably large, generally accompanied by a continued rise in temperature and battery failure, and in the short term accompanied by visible fire or explosion.

[0021] Referring again to FIG. 1, the BMS 20 includes one or more multi-gas sensor array systems on a chip (SoC) or microchip 22 (see FIGS. 1, 2, 4, and 5). As shown in FIG. 2, each microchip 22 can be disposed at a position close to the discharge port 18 in the lithium-ion battery 14 of any embodiment. As described above, the lithium-ion battery 14 can be part of the RESS 10 having a plurality of mutually similar lithium-ion batteries 14 disposed within individual battery modules 12. Thus, in such an embodiment, the BMS 20 can include a plurality of microchips 22 such that there is one microchip for each battery 14, as shown, for example, in FIG. 2. Alternatively, as shown in FIG. 1, each of the microchips 22 can be disposed closer to or inside the discharge ports 12-1, 12-2, 12-3, 12-4 of each module, for example, to detect a plurality of specific gases emitted by the lithium-ion battery 14 at the module level, or disposed closer to or inside the individual battery modules 12-1, 12-2, 12-3, 12-4. In other words, in such an embodiment, each microchip 22 is configured to detect the gases emitted by one or more lithium-ion batteries 14 disposed within a specific battery module 12.

[0022] As shown in Figures 4 and 5, the microchip 22 includes a plurality of silicon chemosensible field-effect transistors (CS-FETs). The CS-FETs 24 are configured to detect functionally significant amounts of multiple types of chemically specific gases emitted by one or more lithium-ion batteries 14. Each individual CS-FET 24 is configured to detect one of the multiple types of gases emitted by the lithium-ion battery 14. Each individual CS-FET 24 is distinguished from the others by specific nanomaterial catalyst elements, shown in Figure 4 as elements 24-1, 24-2, 24-3, and 24-4. Figure 5, in particular, schematically shows a cross-section of an individual sensor 24-4 mounted on the microchip 22, showing a cross-section cut along line 5-5 shown in Figure 4. Within a single CS-FET 24, each of the nanomaterial catalyst elements 24-1, 24-2, 24-3, and 24-4 interacts with the emitted gas. Each of the catalyst elements 24-1, 24-2, 24-3, and 24-4 of the nanomaterial may be composed of a metal such as platinum (for detecting C2H4 gas) or palladium-platinum (for detecting CO gas), or a metal mixture such as nickel-palladium (for detecting H2 gas) or gold-copper (for detecting CO2 gas). The thickness of each catalyst element of the nanomaterial can be in the range of 1 nm to 10 nm.

[0023] As shown in FIG. 5, the microchip 22 includes a silicon transistor body 22A that supports the catalyst elements 24-1, 24-2, 24-3, and 24-4 of the respective nanomaterials. As further shown, the silicon transistor body 22A forms a localized silicon island that supports a plurality of source terminals 22-1 (those for the catalyst elements 24-1, 24-2, 24-3, and 24-4 of the respective nanomaterials are grounded). The silicon transistor body 22A also supports a plurality of drain terminals 22-2, and each of these terminals 22-2 connects the catalyst elements 24-1, 24-2, 24-3, and 24-4 of the respective nanomaterials to a power source via a digital or analog converter (not shown). The catalyst elements 24-1, 24-2, 24-3, and 24-4 of the nanomaterials are electrically isolated from each other and are not directly connected to the power source. Specifically, each of the catalysts 24-1, 24-2, 24-3, and 24-4 of the nanomaterials is configured to interact with a specific gas (without being interfered with by other gases due to the effect of the specific material properties of the catalyst) and detect that specific gas.

[0024] Each CS-FET 24 incorporated in the silicon transistor body 22A is functionally similar to a silicon electronic transistor. An electronic transistor generally has three electrodes, namely a source electrode, a gate electrode, and a drain electrode. The source electrode supplies charge to the transistor. The drain electrode collects or discharges charge, that is, electrons. When a voltage is applied between the drain and the source, charge generally flows from the source electrode to the drain electrode. The role of the gate electrode is to control that flow of charge, and that flow is adjusted by the magnitude of the voltage applied to the gate.

[0025] The operation of each CS-FET24 is similar to that of the electronic transistor described above, except that the charge flow from the source electrode to the drain electrode is controlled by the interaction between a specific gate electrode and a specific gas (rather than a constant voltage being applied to the gate). More specifically, in each CS-FET24, the respective nanomaterial catalysts 24-1, 24-2, 24-3, and 24-4 act as gate electrodes that are not connected to a power source. When the specific gas and the specific nanomaterial catalyst chemically interact, a phenomenon generally described as a "work function change" is induced in the nanomaterial catalyst. The resulting work function change alters the charge flow from source to drain, thereby enabling the detection of the emitted gas.

[0026] The interaction between a specific gas and a catalyst 24-1, 24-2, 24-3, or 24-4 made of a specific nanomaterial modulates or alters the current flowing from each source terminal to each drain terminal within the silicon transistor body 22A. The microchip 22 additionally includes (one or more) microheaters 28 and (one or more) temperature sensors 30, each of which is positioned to surround the individual CS-FETs 24. The microheaters 28 and temperature sensors 30 serve two purposes: (1) to maintain a constant microchip temperature relative to the ambient environment, and (2) to minimize interference from ambient humidity. The microheaters 28 and temperature sensors 30 may be made of tungsten, gold-titanium, or polysilicon with a thickness in the range of 50 to 500 nm. As shown in Figure 5, which shows a cross section cut along the plane 5-5 shown in Figure 4, the microchip 22 may include a concave cavity 31 configured to minimize heat loss from the microheaters and overall microchip power consumption.

[0027] As further shown in Figure 4, the individual CS-FETs 24 may be arranged so as to line up in a single plane on the sensor array microchip 22. In particular, the individual CS-FETs 24 are arranged almost in parallel with respect to one another. Each of the multiple nanomaterial catalysts 24-1, 24-2, 24-3, 24-4 is configured to be sensitive to, i.e., detect, one of several types of gases emitted by the lithium-ion battery 14. Specifically, the individual nanomaterial catalysts 24-1, 24-2, 24-3, 24-4 may be configured to detect emitted gases such as hydrogen, carbon dioxide, carbon monoxide, and ethylene in any order. Although four individual nanomaterial catalysts 24-1, 24-2, 24-3, 24-4 are shown, the microchip 22 may also be configured with fewer or more individual nanomaterial catalysts (indicated by two additional unoccupied sensor spaces in Figure 4).

[0028] Referring further to Figure 1, the BMS 20 also includes a cell monitoring unit (CMU) 32 that works in conjunction with the CS-FETs 24. The CMU 32 may be part of a battery controller network (not shown) configured to manage the operation of the battery module 12. Among various communication, process, and management functions, the CMU 32 is configured, i.e., built and programmed, to receive data 35 from the CS-FETs 24 indicating the detected amount or level of at least one gas emitted by the (one or more) lithium-ion batteries 14. The data signal 35 generated by the microchip 22 is first transmitted to an analog or digital converter (not shown) and then sent to the CMU 32. The signal transmitted by each of the CS-FETs 24, indicating the data 35, may represent several distinctly differentiated stages, namely Stage 1, Stage 2, and Stage 3, depending on the gas emission shown in Figure 3, or the specific detected amount of a particular emitted gas. The transmitted data 35 is superimposed on curve G in Figure 3 to show how the amount detected and transmitted to CMU32 corresponds to the three stages of increasing emission gas volume.

[0029] The microchip 22, including the CS-FETs 24, may be physically wired to a specific CMU 32 (as shown in Figure 1) or it may communicate wirelessly with the CMU. To enable wireless communication, the CMU 32 may include an antenna 32-1 for receiving data 35 from the microchip 22. For this purpose, each microchip may also be provided with its own antenna (not shown). To support the essential management of the battery module 12, the CMU 32 specifically includes a processor and tangible non-volatile memory, which contains instructions programmed for the operation of the BMS 20. This memory may be a suitable storage medium that contributes to providing computer-readable data or process instructions. Such storage media may take various forms, such as non-volatile media and volatile media (but not limited to these).

[0030] Non-volatile media for the CMU32 include, for example, optical or magnetic disks and other permanent memory. Volatile media include, for example, dynamic random access memory (DRAM) which can constitute main memory. Programmed commands within the CMU32 may be transmitted by one or more transmission media (including wired connections consisting of a system bus coupled to the computer's processor), such as coaxial cables, copper wires, and optical fibers, or by wireless connections. Memory for the CMU32 may also include flexible disks, rigid disks, magnetic tape, other magnetic media, CD-ROMs, DVDs, and other optical media. The CMU32 may be configured or equipped with other essential computer hardware such as a high-speed clock, essential analog-to-digital (A / D) and / or digital-to-analog (D / A) converters, input / output circuits and devices (I / O), and appropriate signal conditioning and / or buffer circuits. As a result, one or more algorithms, schematically shown in reference numeral 34, that are requested or accessible by the CMU 32 are stored in the memory of the CMU 32 and can be automatically executed to facilitate the operation of the BMS 20. Specifically, one or more algorithms 34 may include an inventory mode, which may be configured to check the lines actually used for communication with the CS-FETs and the operation of the CS-FETs by monitoring the CS-FETs 24 and / or querying the CS-FETs at predetermined time intervals.

[0031] More specifically, the CMU32 is also configured to compare the received emission gas data 35 with predetermined threshold amounts 38 for each of the emission gases. The predetermined threshold amounts 38 for the emission gases may be empirically determined based on testing of a typical lithium-ion battery such as battery 14 and are programmed within the CMU32. The CMU32 is further configured to trigger a signal 40 indicating an impending failure of one or more lithium-ion batteries 14, which are precursors to battery damage and a sudden rise in temperature, when one or more detected amounts of emission gases (one or more types) emitted by the lithium-ion battery exceed the predetermined threshold amount 38 for the emission gases. Each predetermined threshold amount 38 programmed within the CMU32 may be 10 ppm (parts per million) for H2, 500 ppm for CO2, 10 ppm for CO, and 10 ppm for C2H4 for each individual lithium-ion battery 14. In the embodiment of the BMS20 shown in Figure 1, each predetermined threshold amount 38 programmed in the CMU2 can be adjusted according to the specific number of lithium-ion batteries 14 in a particular battery module 12. In either embodiment, the CMU32 can trigger a signal 40 when the detected amount of at least one of several types of emitted gases exceeds the corresponding threshold amount 38.

[0032] Signal 40 may be an auditory and / or visual sensor signal or alert. For example, signal 40 may be an auditory indicator such as a high-decibel and / or high-frequency alarm. Signal 40 may also be a visual indicator such as a malfunction indicator light (MIL), in which case the resulting digital malfunction code is stored in the memory of the CMU 32. The digital malfunction code stored in the memory of the CMU 32 can be retrieved by an authorized technician or communicated to a central authority, including a database such as an IT cloud server 42 (see Figure 1). As illustrated, the IT cloud server 42 is located separately from the CMU 32 and communicates wirelessly with the CMU 32, for example, via antenna 32-1 and / or using RESS 10, thereby enabling access to and management of the central system. In such an embodiment, the external IT cloud server 42 is part of the BMS 20 that monitors a network of multi-cell rechargeable energy storage systems such as RESS 10 (individual CMUs are similar to the CMU 32). The communication required between each CMU and the IT cloud server 42 may be via a wireless local area network (Wi-Fi) facilitated by cloud edge devices that stay at cellular base stations with short latency, or via a cellular system using Earth-orbiting satellites (not shown).

[0033] The CMU 32 may be configured to detect whether a particular lithium-ion battery 14 is electrically connected to the charger 44 (i.e., receiving a flow of charge from it). The CMU 32 may further be configured to electrically disconnect the lithium-ion battery 14 from the charger 44 in response to a detected amount, represented by data 35, of one or more gases emitted by the battery exceeding one or more predetermined threshold amounts 38 of the emitted gases. The CMU 32 may be configured to disconnect from the charger 44 simultaneously with or in response to triggering or setting a signal 40. Disconnection from the charger 44 can be achieved by opening a switch 46 in the circuit connecting the charger to the lithium-ion battery 14.

[0034] The CMU 32 may further be configured to detect whether the lithium-ion battery 14 is connected to an electrical load 48 (e.g., a vehicle subsystem such as a heating, ventilation, and air conditioning (HVAC) system or a traction motor (not shown)). The RESS 10 may be connected to the electrical load 48 and the CMU 32 via a high-voltage BUS 50 (see Figure 1), particularly when used in motorized vehicles. In such embodiments, the CMU 32 may further be configured to disconnect the lithium-ion battery 14 from the electrical load 48 in response to a detected amount, represented by data 35, of one or more gases emitted by the lithium-ion battery exceeding one or more predetermined threshold amounts 38 of the emitted gases. Disconnecting from the electrical load 48 can be achieved by opening a switch 52 in the circuit connecting the lithium-ion battery 14 to the load. Similar to the situation described above with respect to disconnecting from the charger 44, the CMU 32 may be configured to disconnect from the electrical load 48 simultaneously with or in response to triggering or setting a signal 40.

[0035] The BMS20 may also include a fire suppression system 54 configured to extinguish short-circuit fires. The fire suppression system 54 may include, for example, a sprinkler system with a water supply system or foam supply system that provides appropriate pressure and flow rate to a fluid distribution pump system connected to individual sprinkler units (not shown). In other examples, the fire suppression system 54 may utilize a canister configured to automatically distribute high-pressure inert gas and ultrafine aerosol particles to extinguish short-circuit fires, prevent re-ignition, and reduce the risk of battery housing explosion. The CMU32 may be configured to activate the fire suppression system 54 in response to the detection of (one or more types) of gases released by the lithium-ion battery 14 exceeding (one or more) predetermined threshold amounts 38 of said gases.

[0036] Overall, a multi-gas sensor array microchip 22 having CS-FETs 24 can be used to detect gases emitted from the lithium-ion battery 14 and to provide early notification in the event of lithium-ion battery failure. The multi-gas sensor array microchip 22 incorporated within the BMS 20 of this disclosure provides a more sensitive and cost-effective approach to detecting imminent failure in the lithium-ion battery 14 compared to existing gas detection technologies. By employing the approach of the disclosure programmed within the CMU 32, the safety of individual lithium-ion batteries 14 and lithium-ion battery modules 12 can be improved, and it is easier to protect against lithium-ion battery failure, fire, and explosion that could lead to disaster.

[0037] Figure 6 shows a method 100 for managing the operation of (one or more) lithium-ion batteries 14 via a BMS 20 and detecting imminent failure, which will be described below with reference to the structures shown in Figures 1-5. Method 100 begins in frame 102 by detecting at least one of several specific gases emitted by (one or more) lithium-ion batteries 14 via CS-FET(s) 24 located on a microchip 22. Following frame 102, the method proceeds to frame 104. In frame 104, the method includes receiving data 35 from the CS-FET(s) 24 via a CMU 32 indicating the detected amount of (one or more) gases emitted by at least one lithium-ion battery 14. The method then proceeds from frame 104 to frame 106, in which the method includes comparing the data 35 indicating the detected amount of emitted gas with predetermined threshold amounts 38 of each of the emitted gases programmed in the CMU 32. As explained with respect to Figures 1-5, the predetermined threshold amount 38 programmed within the CMU 32 may be selected from among 10 ppm for H2, 500 ppm for CO2, 10 ppm for CO, and 10 ppm for C2H4.

[0038] Following frame 106, the method proceeds to frame 108. In frame 108, the method includes triggering a signal 40 via the CMU 32 indicating that failure of one or more lithium-ion batteries 14 is imminent when the detected amount of a specific gas emitted by one or more lithium-ion batteries 14, represented by data 35, exceeds a predetermined threshold amount 38 for each of the emitted gases. The method then proceeds to frame 110. In frame 110, the method may include determining or detecting via the CMU 32 whether one or more lithium-ion batteries 14 are connected to a charger 44 and current is flowing from it. After determining that the lithium-ion batteries 14 are connected to the charger 44, the method proceeds to frame 112. In frame 112, the method may include electrically disconnecting one or more lithium-ion batteries 14 from the charger 44 via the CMU 32 in response to the detected amount of the emitted gas exceeding a predetermined threshold amount 38.

[0039] Alternatively, following either frame 108 or 112, the method proceeds to frame 114. In frame 114, the method may include determining or detecting, via the CMU 32, whether (one or more) lithium-ion batteries 14 are connected to the electrical load 48. After determining that (one or more) lithium-ion batteries 14 are connected to the electrical load 48, the method may proceed to frame 116. In frame 116, the method may include electrically disconnecting (one or more) lithium-ion batteries 14 from the electrical load 48 via the CMU 32 in response to the detected amount of released gas exceeding a predetermined threshold amount 38. Following either frame 108, 112, or 116, the method may proceed to frame 118. In frame 118, the method may include activating the fire suppression system 54 via the CMU 32 in response to the detected amount of released gas exceeding a predetermined threshold amount 38.

[0040] As can be understood from the above description, Method 100 enables continuous monitoring of the lithium-ion batteries 14 (one or more) to detect that failure of one or more of the lithium-ion batteries 14 is imminent, and further to issue an alert when such a situation is confirmed. In addition, Method 100 enables limiting the charging and discharging of the batteries 14 (one or more) and further to initiating fire suppression when such failure is confirmed to be imminent. As a result, following any of the flames 108, 112, 116, or 118, Method 100 makes a loop and returns to Flame 104, continuing to monitor the lithium-ion batteries 14 (one or more) via the BMS 20 and continuing to detect gases released by the lithium-ion batteries 14 (one or more) via the CS-FETs 24. Method may also alternatively include Flame 120.

[0041] The drawings and detailed descriptions thereof are supplementary to the disclosure, and the scope of the disclosure is defined solely by the claims. While several best embodiments and some other embodiments for carrying out the claimed disclosure are described in the detailed description of the invention, alternative designs and embodiments exist for carrying out the disclosure as defined in the appended claims. Furthermore, the characteristics of the embodiments shown in each figure or the various embodiments referred to herein should not necessarily be understood as independent embodiments, and other embodiments not described in text or drawings may arise when a characteristic described in one of several examples of an embodiment is combined with one or more other desirable characteristics from other embodiments. Accordingly, such other embodiments are also included within the framework of the appended claims.

Claims

1. In a battery management system configured to detect imminent failure of a lithium-ion battery, A sensor array microchip comprising a plurality of silicon chemosensible field-effect transistors (CS-FETs) configured to detect a plurality of specific gases emitted by the lithium-ion battery, wherein each of the CS-FETs is configured to detect one of the plurality of gases emitted by the lithium-ion battery, A cell monitoring unit (CMU) that can communicate with the above sensor array microchip in an operable manner, Equipped with, The above cell monitoring unit is Receiving at least one of the CS-FETs data indicating the amount of gas detected by the lithium-ion battery mentioned above, The data indicating the detected amount of the released gas is compared with a predetermined threshold amount of the released gas programmed within the CMU, and further, The system is configured to trigger a signal indicating that the lithium-ion battery is on the verge of failure when the detected amount of the emitted gas exceeds a predetermined threshold amount. Battery management system.

2. The above CMU further, Determine whether the above lithium-ion battery is connected to the charger. The battery management system according to claim 1, configured to electrically disconnect the lithium-ion battery from the charger in response to the detected amount of the emitted gas exceeding a predetermined threshold amount for each of the emitted gases.

3. The above CMU further, Determine whether the above lithium-ion battery is connected to an electrical load. The battery management system according to claim 1, configured to disconnect the lithium-ion battery from the electrical load in response to the detected amount of the emitted gas exceeding a predetermined threshold amount for each of the emitted gases.

4. The battery management system is It also includes a fire suppression system configured to extinguish electrical fires, The battery management system according to claim 1, wherein the CMU is further configured to activate the fire suppression system in response to the detected amount of the released gas exceeding a predetermined threshold amount for each of the released gases.

5. The battery management system according to claim 1, wherein the CS-FETs are arranged so as to be aligned in a single plane on the sensor array microchip.

6. Each of the detection gases released by the above lithium-ion battery is hydrogen (H ２ ), carbon dioxide (CO2) ２ ), carbon monoxide (CO) and ethylene (C) ２ H ４ The battery management system according to claim 5, which is selected from a list including ).

7. The predetermined threshold amount programmed within the above CMU is H ２ Regarding 10 ppm, CO ２ 500 ppm for CO, 10 ppm for CO, and C ２ H ４ The battery management system according to claim 6, wherein the value is selected from among 10 ppm.

8. The battery management system according to claim 1, wherein the lithium-ion battery is part of a multi-cell rechargeable energy storage system (RESS) having a plurality of lithium-ion batteries arranged in individual battery modules, the sensor array microchip is positioned in close proximity to the individual battery modules within the RES, and the sensor array microchip is configured to detect a plurality of specific gases emitted by the lithium-ion battery at the module level.

9. The battery management system according to claim 1, wherein the lithium-ion battery includes a housing having an exhaust port configured to discharge the gas, and the sensor array microchip is positioned in close proximity to the exhaust port.

10. The battery management system according to claim 9, wherein the housing is configured as one of a pouch, a prismatic casing, and a cylindrical casing.

11. The sensor array microchip further includes at least one microheater and at least one temperature sensor arranged to surround the plurality of CS-FETs, The battery management system according to any one of claims 1 to 10, characterized in that the at least one microheater and at least one temperature sensor are configured to maintain a constant temperature of the sensor array microchip relative to the ambient environment and to minimize interference from ambient humidity.

12. The battery management system according to claim 11, further comprising a concave cavity configured to minimize the heat loss of the microheater and the power consumption of the sensor array microchip.

13. A method for managing the operation of a lithium-ion battery and detecting when a lithium-ion battery is about to fail, The method is, A step of detecting a gas emitted by a lithium-ion battery via at least one of a plurality of silicon chemosensible field-effect transistors (CS-FETs) arranged on a sensor array microchip, wherein each of the plurality of CS-FETs is configured to detect one of a plurality of specific gases emitted by the lithium-ion battery; The steps include receiving data from the CS-FET via a cell monitoring unit (CMU) that communicates with the CS-FET in an operable manner, indicating the amount of gas detected by the lithium-ion battery, The steps include comparing data indicating the amount of gas to be emitted via the above-mentioned CMU with a predetermined threshold amount of the emitted gas programmed within the CMU, The steps include: via the above-mentioned CMU, triggering a signal indicating that failure of the lithium-ion battery is imminent when the detected amount of the emitted gas exceeds a predetermined threshold amount of the emitted gas; A method that includes this.

14. The steps include determining whether the lithium-ion battery is connected to the charger via the CMU, The steps include electrically disconnecting the lithium-ion battery from the charger in response to the detected amount of the emitted gas exceeding a predetermined threshold amount for each of the emitted gases via the CMU, The method according to claim 13, further comprising:

15. The steps include determining whether the lithium-ion battery is connected to an electrical load via the above-mentioned CMU, The steps include disconnecting the lithium-ion battery from the electrical load in response to the detection amount of the emitted gas exceeding a predetermined threshold amount for each of the emitted gases via the CMU, The method according to claim 13, further comprising:

16. The method according to claim 13, further comprising the step of activating a fire suppression system in response to the detection amount of the released gas via the CMU exceeding a predetermined threshold amount of each of the released gases.

17. The method according to claim 13, wherein the CS-FETs are arranged on the sensor array so as to be aligned in a single plane.

18. Each of the gases released and detected by the lithium-ion battery is hydrogen (H ２ ), carbon dioxide (CO ２ ), carbon monoxide (CO) and ethylene (C ２ H ４ ), and is selected from the list including them. The method according to claim 17.

19. The predetermined threshold amount programmed within the above CMU is H ２ Regarding 10 ppm, CO ２ 500 ppm for CO, 10 ppm for CO, and C ２ H ４ The method according to claim 18, wherein the concentration is selected from among 10 ppm.

20. The above lithium-ion battery is part of a multi-cell rechargeable energy storage system (RESS) having multiple lithium-ion batteries arranged within individual battery modules. The above sensor array microchip is positioned within the RESS in close proximity to the individual battery modules, and furthermore, The method according to claim 13, wherein the step of detecting at least one of a plurality of specific gases emitted by the lithium-ion battery includes detecting the plurality of specific gases emitted by the lithium-ion battery at a module level.

21. The method according to claim 13, wherein the lithium-ion battery includes a housing having an exhaust port configured to discharge the gas, and the sensor array microchip is positioned in close proximity to the exhaust port.

22. The method according to claim 21, wherein the housing is configured as at least one of a pouch, a prismatic casing, and a cylindrical casing.

23. The sensor array microchip further includes at least one microheater and at least one temperature sensor arranged to surround the plurality of CS-FETs, The method is, The method according to any one of claims 13 to 22, further comprising the step of using at least one microheater and at least one temperature sensor to maintain a constant temperature of the sensor array microchip relative to the ambient environment and to minimize interference from ambient humidity.

24. The sensor array microchip further includes a concave cavity, The method is, The method according to claim 23, further comprising the step of using the concave cavity described above to minimize the heat loss of the microheater and the power consumption of the sensor array microchip.

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