Battery Sensor Module with Pressure-Sensitive Membrane
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Solution Overview
Problem
Battery cells are prone to rupture or explosion due to adverse conditions such as overload, excessive discharge current, and mechanical electrolyte disintegration, which can lead to dangerous gas buildup and increased internal pressure, necessitating an early detection system to prevent such incidents.
Innovation Solution
A sensor module with a pressure-sensitive membrane and gas filter is integrated into the battery cell packaging, capable of detecting gas pressure differences and rupturing when pressure limits are exceeded, triggering a disconnection of the current flow to prevent further damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor module is integrated into the battery cell packaging to detect gas pressure, then safety is improved through early detection, but device complexity increases due to additional components
Solution Approach 1:
The sensor module merges multiple functions into a single integrated unit: the pressure-sensitive membrane detects gas pressure, the gas filter selectively allows specific gases to reach the sensor, and the evaluation unit processes signals and triggers disconnection. This consolidation improves reliability while managing complexity through functional integration.
Solution Approach 2:
The pressure-sensitive membrane acts as an intermediary element that converts gas pressure into a detectable signal. The gas filter serves as another intermediary that selectively permits certain gases to reach the sensor while blocking others, enabling specific hazard detection without requiring direct sensor exposure to all battery contents.
2Measurement precision
If the sensor module includes a gas filter to detect specific gas types, then measurement precision is improved, but device complexity increases due to additional filtering components
Solution Approach 1:
The gas filter introduces local quality by selectively permitting specific gas types to reach the sensor while blocking others. This localized filtering property enables the sensor to detect particular hazardous gases (such as those indicating electrolyte decomposition) with high precision without needing to analyze all gas compositions.
Solution Approach 2:
The system replaces complex gas analysis mechanisms with a simpler pressure detection approach. Instead of using sophisticated sensors to identify and measure multiple gas compositions, the invention uses a pressure-sensitive membrane combined with selective gas filtering to infer the presence of hazardous conditions through pressure changes caused by specific gas generation.
3Reliability
If the membrane is designed to rupture at a specific pressure threshold, then reliability is improved through fail-safe protection, but the structural integrity of the packaging is compromised
Solution Approach 1:
The pressure-sensitive membrane is pre-configured with a specific rupture threshold that acts as a fail-safe protection mechanism. Before the battery cell can reach dangerous pressure levels that would cause catastrophic failure, the membrane ruptures to release pressure, thereby cushioning against worse outcomes. This prior preparation ensures reliability by guaranteeing pressure relief at a safe threshold.
Solution Approach 2:
The membrane rupture, which might initially seem to compromise structural integrity, is actually converted into a beneficial safety feature. The controlled rupture serves as a pressure relief valve that prevents more severe structural damage, battery explosion, or release of dangerous substances. The apparent weakness becomes a strength by providing a controlled failure mode that protects the overall system.
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 sensor module effectively detects increased gas pressure and specific gas types, enabling early intervention to prevent battery cell rupture and explosion, ensuring safety by disconnecting power when hazardous conditions are detected.
Implementation Method 1
a sensor element (64) arranged on an inner wall (51i) of the enclosure (51)
Implementation Method 2
The sensor module (50) comprises a membrane (59) which is arranged to cover the opening (52) in the casing (46)
Data Source
AI summary
A sensor module includes an enclosure adapted to hermetically seal an opening or a hole on the outer surface of a casing or packaging, a sensor element and a membrane. The membrane is arranged between the enclosure and the opening or hole of the casing or packaging.