Battery Module Swelling Detection and Fire Suppression
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Solution Overview
Problem
Conventional battery management systems fail to effectively monitor and mitigate internal pressure changes in battery cells, which can lead to swelling and potential fires, as they primarily focus on voltage and temperature monitoring rather than the internal state of the cells.
Innovation Solution
The implementation of a battery module with a sensor that detects swelling, using high-frequency AC power for cell balancing, and a water-based fire suppression system within the battery rack to prevent and control fires, along with an exhaust duct for gas and heat removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery management systems only monitor voltage and temperature, then the system complexity is low, but the ability to detect internal cell state changes and prevent fires is insufficient
Solution Approach 1:
The patent embeds multiple sensing capabilities within the battery module structure itself. Swelling detectors are integrated into the module housing, and pressure sensors are incorporated into the cell assembly, creating a nested monitoring system where sensors are embedded within the battery structure rather than being external add-ons. This nesting approach enhances fire prevention capability while minimizing the increase in overall system complexity.
Solution Approach 2:
The battery management system is designed to perform multiple functions: voltage monitoring, temperature monitoring, swelling detection, and pressure sensing. By integrating these diverse monitoring capabilities into a unified system, the patent achieves comprehensive fire prevention while avoiding the complexity of separate independent systems. The multi-functional approach allows a single system to address multiple failure modes.
2Measurement precision
If swelling detectors are integrated into battery modules, then early detection of abnormal swelling is enabled, but the device complexity increases
Solution Approach 1:
Swelling detectors are integrated directly into the battery module housing and cell assembly structures. The detectors are embedded within existing structural components rather than being separate external devices, allowing precise measurement of cell swelling while minimizing the increase in overall module complexity. The sensing elements are incorporated into the modular design.
Solution Approach 2:
The swelling detection system focuses monitoring capabilities specifically at the battery module and cell levels where swelling occurs, rather than implementing comprehensive monitoring throughout the entire battery system. This localized approach provides precise swelling detection at critical points while avoiding the complexity of system-wide instrumentation.
3Object-affected harmful factors
If water fire suppression systems are implemented in battery racks, then fire control and prevention of spread is improved, but the system complexity and water management requirements increase
Solution Approach 1:
The fire suppression system is divided into modular units at the battery rack level, with each rack having its own water-based suppression capability. This segmentation allows fire control to be localized to affected racks, preventing spread to other racks, while keeping each individual suppression unit relatively simple in design and operation.
Solution Approach 2:
The system uses water, a common and simple substance, to suppress battery fires. By implementing water-based suppression systems with automatic detection and activation, the patent converts a simple substance into an effective fire control mechanism, achieving fire spread prevention without requiring complex specialized suppression agents or systems.
4Reliability
If high frequency AC power is used for cell balancing, then isolation transformers can be used improving safety, but the system complexity increases
Solution Approach 1:
Isolation transformers are introduced as intermediary devices in the cell balancing circuitry. These transformers provide galvanic isolation between the high-frequency AC power source and the battery cells, enhancing safety by preventing direct electrical connections while still enabling effective cell balancing. The intermediary component adds a layer of safety without fundamentally changing the cell balancing function.
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
This solution enables early detection of abnormal swelling, halting battery operations to prevent fires, effectively managing and extinguishing potential fires within the battery module and rack, thereby ensuring safety and preventing damage.
Implementation Method 1
a battery module having a sensor that detects swelling of a battery cell
Implementation Method 2
high frequency AC power is used as a power source for balancing the battery module cells
Implementation Method 3
a top cover that collects water and directs this water to plates of the battery module to cool the battery
Implementation Method 4
a water fire suppression system having a cascading water flow among the battery modules, which provides cooling in the event of a battery cell fire
Implementation Method 5
an exhaust duct to remove gases and/or heat and direct these gases and/or heat outside of the room, container, building, etc. that houses the battery rack
Data Source
AI summary
Provided is a battery module and battery rack having enhanced fire safety features. The battery module includes a swelling/pressure sensor that detects swelling of a battery cell. An output signal of the sensor is used to halt operation of a battery rack/battery system containing the battery module and prevent charging and discharging of the battery module. In an embodiment, the battery module uses an AC-to-AC power supply to provide AC frequency power for balancing battery cells of the battery module. In an embodiment, the battery rack includes an internal water fire suppression system that provides battery cooling in the event of a battery cell fire to prevent the spread and/or reigniting of the fire.