Battery Cell Deformation Sensing for Early Thermal Runaway Detection

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Solution Overview

Problem

Lithium-ion batteries in electric vehicles are prone to thermal runaway due to self-heating, which can cause severe damage, including fires, posing a significant risk to occupants.

Innovation Solution

An apparatus with a sensing module, implemented using a strain gauge, detects deformation in battery cells and transmits data to a printed circuit board, which is then analyzed by a controller to predict thermal runaway, triggering a warning alarm to alert occupants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a battery management system monitors voltage and temperature of battery cells, then battery performance can be optimized and basic safety can be ensured, but thermal runaway cannot be detected in time because these parameters only reflect normal operating conditions

Engineering Contradiction:

Improvethermal runaway detection capabilityVSAvoidpre-thermal runaway deformation signal

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

A sensing module is introduced as an intermediary component between the battery cell and the battery management system. This sensing module specifically detects deformation of the battery cell using a strain gauge, providing early warning signals of thermal runaway before traditional voltage and temperature monitoring can detect the danger. The sensing module transmits deformation information to the BMS, enabling timely detection and response.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If traditional voltage and temperature monitoring is used, then the system structure remains simple, but the detection precision for thermal runaway is insufficient

Engineering Contradiction:

Improvethermal runaway detection precisionVSAvoidsensing module structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The detection system is segmented into specialized components: a sensing module for detecting battery cell deformation, a printed circuit board for signal processing, and the battery management system for decision-making. This segmentation allows each component to focus on a specific function, improving overall detection precision while keeping individual component complexity manageable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces traditional electrical monitoring (voltage, temperature) with mechanical deformation detection using a strain gauge. This substitution enables detection of physical changes in the battery cell that precede thermal runaway, providing earlier and more accurate warning signals.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Object-affected harmful factors

If no early warning system is installed, then the device complexity is low, but the harmful effects of thermal runaway (fire, damage) are severe

Engineering Contradiction:

Improvefire risk and damage severityVSAvoiddetection and warning system

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The sensing module performs preliminary detection of battery cell deformation before thermal runaway occurs. By detecting mechanical changes in advance, the system can trigger early warnings and initiate protective measures, preventing the severe harmful effects of fire and damage that would occur without such early intervention.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system establishes a feedback loop where the sensing module continuously monitors battery cell deformation and transmits information to the battery management system. When deformation exceeds safe thresholds, the BMS receives real-time feedback and activates warning signals, creating a closed-loop safety mechanism that responds dynamically to battery conditions.

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The apparatus effectively detects thermal runaway in battery cells, enabling timely warnings to occupants and reducing the risk of damage and fire hazards.

Implementation Method 1

A sensing module which detects deformation amount of the battery cell may be provided in the battery cell

Methodology Applied

Scientific EffectStrain gauge: Piezoresistive Effect

Data Source

PatentUS11799138B2Apparatus for detecting thermal runaway of battery for electric vehicle

Publication Date: 2023.10.24 HYUNDAI MOTOR CO LTD

AI summary

An apparatus for detecting a thermal runaway of a battery for an electric vehicle may include: an exterior case; a plurality of battery cells provided inside the exterior case; a sensing module provided in one of the plurality of battery cells and detecting deformation amount of the battery cell; and a printed circuit board transmitting a voltage and a temperature of the battery cell, and the deformation amount of the battery cell detected by the sensing module, to a battery management system.