Battery Pack Force Sensing for Early Thermal Runaway Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery monitoring methods, such as voltage and temperature-based systems, suffer from low signal-to-noise ratios, slow response times, and false alerts, making it difficult to accurately detect abnormalities in battery pack modules, particularly thermal runaway events.
Innovation Solution
Implementing force sensors to monitor compression forces within battery pack modules, which provide a high level of information for detecting abnormalities and predicting thermal runaway events, and adjusting compression forces during assembly and use to ensure target levels are met.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If voltage and temperature-based monitoring methods are used, then the system can monitor battery parameters, but the signal-to-noise ratio is low and detection accuracy is poor
Solution Approach 1:
The patent replaces electrical and thermal sensing systems with a mechanical sensing system. Force sensors measure mechanical compression forces on battery cells to detect abnormalities, leveraging the mechanical expansion/contraction of cells during charging and discharging cycles. This mechanical approach provides higher signal-to-noise ratio and detection accuracy compared to voltage and temperature-based methods.
2Speed
If voltage and temperature-based monitoring methods are used, then the system can detect battery abnormalities, but the response time is slow
Solution Approach 1:
The patent replaces slow thermal and electrical monitoring with fast mechanical force sensing. Force sensors detect real-time changes in compression forces on battery cells, providing immediate response to abnormalities such as swelling or thermal runaway events, significantly reducing detection delay compared to voltage and temperature methods.
3Reliability
If voltage and temperature-based monitoring methods are used, then the system can monitor battery state, but false alerts are frequent
Solution Approach 1:
The patent replaces electrical and thermal monitoring with mechanical force sensing to eliminate false alerts. Force sensors measure actual physical changes in battery cell compression, providing reliable detection of true abnormalities without the false positives that plague voltage and temperature-based systems.
4Measurement precision
If force sensors are implemented to monitor compression forces, then detection accuracy improves, but device complexity increases
Solution Approach 1:
The patent replaces complex electrical and thermal sensor networks with simpler mechanical force sensors. The force sensing system requires fewer sensors and less complex signal processing infrastructure while providing superior detection accuracy, thereby reducing overall system complexity despite the novel sensing approach.
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
Force monitoring systems offer accurate and reliable detection of battery parameters like SOC, SOH, and thermal runaway events, enabling proactive mitigation and prevention of thermal runaway.
Implementation Method 1
one or more force sensors configured to generate at least one force signal indicative of force on the cells within the battery pack module
Data Source
AI summary
A system includes a battery pack module and a control module. The battery pack module is configured to be implemented in a battery pack. The battery pack module includes cells and one or more force sensors configured to generate at least one force signal indicative of force on the cells within the battery pack module. The control module is configured to: receive the at least one force signal; based on the at least one force signal, detect a state of the cells; and based on the detected state of the cells, at least one of i) modify the state of the cells, ii) generate an alert message, and iii) perform a mitigation operation to address a detected abnormality of the cells.