Battery Cell Assembly With Pressure Pads for Abnormal State Detection
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Solution Overview
Problem
Existing battery systems lack effective means to detect abnormal cell voltage and pressure changes, which can lead to dangerous conditions such as heating, smoking, and explosion, necessitating a solution to announce and mitigate such abnormalities.
Innovation Solution
A battery system with pressure sensing pads connected in parallel to each battery cell, featuring sensors with varying resistance based on applied pressure, and a battery management system (BMS) that monitors cell voltages and determines abnormal states by detecting threshold voltage decreases, triggering protective actions like stopping operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure sensing pads are attached to battery cells to detect abnormalities, then safety and reliability are improved, but device complexity increases
Solution Approach 1:
The pressure sensing pad integrates multiple functions into a single component: it serves as both a pressure sensor and an electrical connection element. The pad is electrically connected to the battery cell terminal, combining the sensing function with the electrical connection function, thereby reducing the need for separate components and wiring.
Solution Approach 2:
The pressure sensing pad performs multiple functions simultaneously: it detects pressure changes on the battery cell surface, provides electrical connection to the cell terminal, and serves as a mounting structure. This multi-functionality reduces overall system complexity while improving safety monitoring capabilities.
2Measurement precision
If resistance-based pressure sensors are used to detect cell swelling, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The invention replaces complex mechanical pressure sensing mechanisms with an electrical resistance-based sensing approach. The pressure sensor utilizes changes in electrical resistance in response to applied pressure, eliminating the need for mechanical linkages, moving parts, or complex mechanical signal transmission systems.
Solution Approach 2:
The pressure sensor operates by detecting changes in electrical resistance parameter in response to pressure changes. As pressure is applied to the sensor, its resistance changes predictably, providing a direct electrical signal that correlates with the pressure magnitude, enabling precise measurement through simple resistance monitoring.
3Measurement precision
If multiple pressure sensors are deployed on battery cells, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The pressure sensing pad integrates the pressure sensing function with the electrical connection function into a single component, reducing the total number of parts needed. This integration eliminates the need for separate pressure sensor housings, mounting brackets, and additional wiring harnesses, thereby reducing manufacturing costs.
Solution Approach 2:
The pressure sensing pad is designed as a simple, inexpensive component that can be easily manufactured and replaced if needed. The resistance-based pressure sensing element uses straightforward materials and construction methods, making it cost-effective compared to more complex sensor alternatives.
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
Enables early detection of battery abnormalities, preventing dangerous conditions by measuring cell voltage and sensing pressure changes, allowing for timely protective measures to be taken.
Implementation Method 1
a sensor unit including a pressure sensor attached to the external surface of a corresponding battery cell among the plurality of battery cells, and having resistance which varies according to the applied pressure
Data Source
AI summary
Disclosed is a battery system including: a battery pack including a plurality of battery cells, and a plurality of pressure sensing pads connected to the plurality of battery cells in parallel, and attached to external surfaces of the plurality of battery cells, and having resistance values which vary according to an applied pressure; and a battery management system (BMS) configured to derive a plurality of cell voltages for the plurality of battery cells, respectively, and determine that the battery pack is in an abnormal state when at least one of the plurality of derived cell voltages is equal to or less than a threshold voltage.