Insulated Sensor Segmentation for Battery Pressure Detection

Solution Overview

Problem

Existing battery cells lack precise detection and response mechanisms to prevent safety-critical states caused by external conductive objects, leading to potential electrical shorts or substance leakage, which can increase injury and damage risks.

Innovation Solution

The integration of electrically insulated contact sensor elements within the battery cell, which can detect the precise location of pressure application by external conductive objects, allowing for selective initiation of safety measures such as discharging or bypassing to prevent damage and ensure safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If contact sensor elements are electrically connected to each other, then the detection mechanism is simpler, but the precise location detection of pressure application is lost

Engineering Contradiction:

Improvelocation detection precisionVSAvoidsensor element configuration

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The sensor system is segmented into multiple electrically insulated contact sensor elements (S1, S2, S3, S4) arranged at different locations on the housing. Each element is electrically isolated from others, allowing independent detection of pressure application points. This segmentation enables precise location detection while maintaining system functionality through distributed sensing points.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An insulating layer (I) is introduced as an intermediary between the contact sensor elements and the housing, and between adjacent sensor elements. This intermediary layer provides electrical insulation while allowing mechanical pressure to transmit to the sensor elements, enabling location detection without electrical interference between sensors.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If no insulating layer is used, then the device structure is simpler, but electrical short circuits between sensor elements and housing cannot be prevented

Engineering Contradiction:

Improveelectrical insulation reliabilityVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

An insulating layer (I) is introduced as an intermediary between the contact sensor elements and the housing, and between adjacent sensor elements. This intermediary layer provides electrical insulation while allowing mechanical pressure to transmit to the sensor elements, enabling location detection without electrical interference between sensors.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulating properties are applied locally at critical interfaces where electrical isolation is needed - specifically between contact sensor elements and the housing, and between adjacent sensor elements. This localized application of insulation maintains reliability without requiring complete insulation throughout the entire device structure.

Inventive Principle:

Principle #3Local quality

3Area of stationary object

If sensor elements are arranged closer together, then the detection coverage is better, but the risk of electrical interference increases

Engineering Contradiction:

Improvedetection coverage areaVSAvoidelectrical isolation reliability

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The sensor system is segmented into multiple electrically insulated contact sensor elements (S1, S2, S3, S4) arranged at different locations on the housing. Each element is electrically isolated from others, allowing independent detection of pressure application points. This segmentation enables precise location detection while maintaining system functionality through distributed sensing points.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An insulating layer (I) is introduced as an intermediary between the contact sensor elements and the housing, and between adjacent sensor elements. This intermediary layer provides electrical insulation while allowing mechanical pressure to transmit to the sensor elements, enabling location detection without electrical interference between sensors.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 efficient identification and mitigation of safety-critical states by determining the exact location of mechanical deformation, reducing the risk of injury and damage by allowing for timely and targeted safety measures like discharging or bypassing before significant damage occurs.

Implementation Method 1

contact sensor elements for detecting elements which bear on the contact sensor elements or apply pressure to the contact sensor elements

Methodology Applied

Scientific EffectPressure detection:

Data Source

PatentUS10147929B2Device for increasing safety when using battery systems

Publication Date: 2018.12.04 ROBERT BOSCH GMBH

AI summary

A battery cell (BZ), in particular a lithium-ion battery cell, wherein the battery cell (BZ) has a number of contact sensor elements (S) for detecting elements (N) which bear on the contact sensor elements (S) or apply pressure to the contact sensor elements (S), wherein the contact sensor elements (S) are electrically insulated from one another.