Battery Module Pressure Sensor Layout for Cell Swelling Detection
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Solution Overview
Problem
Conventional battery modules are unable to accurately detect abnormal swelling pressures across the entire surface of battery cells due to localized pressure sensing, which can lead to surface damage and increased risk of ignition or explosion during sharp temperature rises.
Innovation Solution
A battery module design featuring a pressure sensor unit with protruding nodes and a surface pressure transmission plate, made of lightweight plastic, that covers the entire surface of the battery cell, along with a sensitivity adjusting member to prevent damage and ensure accurate pressure measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pressure sensor is inserted between two battery cells to sense pressure, then the pressure sensor can detect local pressure, but it cannot detect the overall surface pressure of the battery cell and may cause surface damage
Solution Approach 1:
The pressure sensor is divided into multiple pressure sensing nodes distributed across the surface of the battery cell. Each node independently senses pressure at its location, and the controller integrates data from all nodes to determine overall surface pressure, achieving comprehensive coverage without concentrating force at a single point
Solution Approach 2:
A pressure transmission plate is introduced as an intermediary component between the pressure sensing nodes and the battery cell surface. This plate distributes the contact force uniformly across the battery cell surface, preventing localized pressure concentration and surface damage while still allowing accurate pressure measurement through the sensing nodes
2Measurement precision
If a pressure sensor covers the entire surface of the battery cell to detect overall pressure, then accurate detection of thermal propagation is possible, but the device complexity increases
Solution Approach 1:
Instead of using a single continuous pressure sensor covering the entire surface, the system segments the sensing function into multiple discrete pressure sensing nodes. These nodes are distributed across the battery cell surface, each performing simple local pressure sensing, while the controller performs the complex task of integrating data from all nodes to determine overall surface pressure
Solution Approach 2:
The pressure transmission plate serves multiple functions: it provides a flat mounting surface for the pressure sensing nodes, distributes pressure uniformly across the battery cell surface, and protects the sensing nodes from direct contact with the battery cell, reducing surface damage risk
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 the detection of abnormal surface pressures during swelling, preventing surface damage and ensuring safe operation by monitoring pressure changes and stopping the module when thresholds are exceeded, thereby preventing potential fires or explosions.
Implementation Method 1
a pressure sensor unit disposed between one battery cell and another battery cell facing the one battery cell, and having a plurality of pressure sensing nodes protruding toward the another battery cell
Data Source
AI summary
A battery module includes a cell stack having a plurality of battery cells stacked in one direction; a pressure sensor unit disposed between one battery cell and another battery cell facing the battery cell, and having a plurality of pressure sensing nodes protruding toward the other battery cell; and a surface pressure transmission plate disposed between the pressure sensor unit and the other battery cell, and having a flat surface facing the plurality of pressure sensing nodes.