Battery Cell Pressure Sensor Embedding
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Solution Overview
Problem
Existing battery cells for electric vehicles face challenges in integrating pressure sensors without compromising the seal integrity, which can lead to functional failures and increased risks of electrical shorting and leakage.
Innovation Solution
Embedding pressure sensors and their wires within the inner surface of the battery cell housing, allowing for pressure readings without forming holes that could disrupt the seal or impact the functionality of current interrupter devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure sensors are integrated into the battery cell housing, then pressure monitoring capability is improved, but the seal integrity deteriorates due to holes or openings required for sensor installation
Solution Approach 1:
The patent introduces a flexible membrane as an intermediary element between the battery cell interior and the pressure sensor. The membrane transmits pressure changes from the electrolyte to the sensor while maintaining the seal integrity of the housing. This allows pressure monitoring without creating holes or openings that would compromise the seal.
Solution Approach 2:
The pressure sensor is embedded within a recess in the housing, and the flexible membrane is positioned over the recess to cover the sensor. This nested arrangement allows the sensor to be integrated into the housing structure without protruding or creating external openings, thereby maintaining seal integrity while enabling pressure monitoring.
2Loss of information
If pressure sensor wires are routed through the housing, then pressure data transmission is improved, but the risk of electrical shorting and leakage increases
Solution Approach 1:
The flexible membrane serves as an intermediary that allows pressure information to be transmitted to the sensor without requiring wire penetrations through the housing seal. The membrane transmits the mechanical pressure signal while the wiring remains external to the sealed environment, eliminating the pathway for electrical shorting and leakage.
Solution Approach 2:
Instead of routing wires through the housing wall (one-dimensional penetration), the patent uses a flexible membrane that responds to pressure changes in a different dimensional manner. The membrane deforms in response to pressure and transmits this information to the sensor without requiring a physical wire pathway through the seal, thereby eliminating the harmful effect of wire penetrations.
Data Source
AI summary
Provided herein are battery cells for battery packs in electric vehicles. The battery cell can include a housing having a first end, a second end, and an inner surface. The housing can define an inner region and an electrolyte can be disposed in the inner region of the housing. A gasket can couple a lid with the first end of the housing to seal the battery cell. The inner surface can include a recess and a groove. The groove can form a path from the recess to an egress point on the first end of the housing. A pressure sensor can be disposed in the recess. The pressure sensor can couple with a pressure sensor wire disposed in the groove and the pressure sensor wire can extend from the recess and past the egress point on the first end of the housing to provide sensed pressure information.