Li-Ion Battery Pack Safety via Shock and Gas Detection
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Solution Overview
Problem
Li-ion battery packs in medical devices are susceptible to thermal run-away due to mechanical, thermal, and electrical abuse, leading to potential fires or explosions, which existing safety features may not be able to prevent quickly enough, especially in harsh environments and when used with non-original chargers.
Innovation Solution
Incorporating shock sensors and gas sensors into the battery management system to detect impacts and gas leaks, with the system capable of performing remediation actions such as shutting down the battery pack or transmitting alerts to prevent catastrophic failures, and using a wireless transceiver to communicate with a battery management center.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing safety features (PTC switches, vent ports, shutdown separators) are used in Li-ion battery packs, then basic safety protection is provided, but the response time is insufficient to prevent thermal run-away in harsh environments
Solution Approach 1:
The patent implements preliminary action by using shock sensors to detect mechanical impacts and gas sensors to detect early gas evolution before thermal run-away occurs. This early detection enables the BMS to take preventive action (such as disconnecting the battery) before the catastrophic failure mode develops, thus improving response time while maintaining reliability
Solution Approach 2:
The patent applies feedback by continuously monitoring multiple parameters (shock, gas evolution, temperature, voltage) and using this information to dynamically control the battery management system. The BMS receives feedback from sensors and adjusts its operation accordingly, enabling faster response to developing failure conditions compared to passive safety features alone
2Loss of time
If shock sensors and gas sensors are added to detect faults early, then response time and detection capability are improved, but device complexity increases
Solution Approach 1:
The patent applies universality by integrating multiple sensing functions (shock detection, gas detection, temperature monitoring, voltage monitoring) into a unified battery management system. The BMS serves as a multi-functional controller that processes inputs from various sensors and coordinates the remediation response, thereby managing complexity through functional integration rather than separate independent systems
Solution Approach 2:
The patent merges the safety monitoring functions by combining shock sensors, gas sensors, temperature sensors, and voltage monitoring into a single integrated BMS architecture. This consolidation reduces the overall system complexity compared to having separate independent safety systems, while enabling coordinated response to multiple failure modes simultaneously
3Reliability
If the battery management system performs remediation actions upon fault detection, then safety and reliability are improved, but the system requires more sophisticated control logic
Solution Approach 1:
The BMS is pre-programmed with remediation strategies that are automatically executed upon detection of specific fault conditions. For example, upon detecting gas evolution or severe shock, the BMS automatically disconnects the battery or activates alarms without requiring complex real-time decision-making, thus improving safety while managing control logic complexity through pre-planned response protocols
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 solution effectively detects and responds to potential failures before they escalate into fires or explosions, ensuring safer operation of medical devices by minimizing the risk of thermal run-away and providing timely alerts for battery replacement or immediate action.
Implementation Method 1
at least one gas sensor configured to measure a gas evolving from the plurality of electrical battery cells
Implementation Method 2
a shock sensor configured to measure an impact on the battery pack
Data Source
AI summary
A battery pack (12) includes one or more electrical battery cells (18). A battery management system (20) includes at least one electronic processor (24) configured to monitor parameters of the battery pack. At least one fault detection sensor includes at least one of: at least one gas sensor (36) configured to measure a gas evolving from the plurality of electrical battery cells; and a shock sensor (30) configured to measure an impact on the battery pack. A housing (16) encloses the plurality of electrical battery cells, the battery management system, and the at least one fault detection sensor. The battery management system is configured to perform a remediation action responsive to detection of a fault by the at least one fault detection sensor.