Cell Temperature Monitoring via Internal Nesting

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Solution Overview

Problem

Existing energy storage systems face challenges in accurately monitoring temperature and balancing charge across multiple energy storage units, leading to potential cell abuse, reduced cycle life, and inefficient use of energy.

Innovation Solution

A system comprising a battery management controller and cell balancing circuits that measure and control voltage, current, and temperature across energy storage units, enabling real-time charge balancing and temperature monitoring, using temperature sensors and internal estimation methods to ensure safe operation and equalization of cell voltages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If temperature sensors are placed externally on cell packs, then the system structure is simplified and cost is reduced, but temperature measurement accuracy deteriorates due to thermal lag and external heat sources

Engineering Contradiction:

Improvesystem structureVSAvoidtemperature measurement accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The temperature sensor is nested inside the cell pack structure, specifically positioned between individual cells or within cell groups. This internal placement allows the sensor to be surrounded by the cells themselves, which act as thermal mass to reduce external thermal interference while maintaining structural integration.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

Thermal interface materials or conductive structures are introduced as intermediaries between the temperature sensor and the cells. These intermediaries improve thermal coupling between the sensor and cells while isolating the sensor from direct contact with external heat sources generated by battery management circuitry.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If multiple temperature sensors are distributed throughout the cell pack, then temperature monitoring coverage is improved, but system complexity and cost increase

Engineering Contradiction:

Improvetemperature monitoring coverageVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Temperature sensors are strategically positioned at specific locations within the cell pack where thermal conditions differ most significantly. Rather than uniform distribution, sensors are placed in high-risk areas such as between cell groups with different thermal characteristics or near heat-generating components, providing targeted monitoring where it is most needed.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The temperature sensor system is designed to serve multiple functions: monitoring cell temperature for safety, detecting thermal runaway conditions, providing data for battery management algorithms, and enabling predictive maintenance. This multi-functionality justifies the sensor distribution and reduces the need for separate monitoring systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Stability of the object's composition

If charge balancing is implemented across all cells, then cell voltage uniformity is improved and cycle life is extended, but energy loss increases due to resistive heating

Engineering Contradiction:

Improvecell voltage uniformityVSAvoidenergy loss

Core Design Contradiction:

Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The charge balancing system dynamically adjusts balancing parameters such as current magnitude, duration, and activation thresholds based on real-time cell voltage measurements and state of charge calculations. By changing these parameters adaptively rather than using fixed balancing protocols, the system achieves voltage uniformity while minimizing unnecessary energy dissipation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Charge balancing is applied selectively to only those cells that require it, rather than uniformly to all cells. The system identifies cells with voltage deviations beyond acceptable thresholds and applies balancing current only to those specific cells, reducing overall energy loss while maintaining voltage uniformity across the pack.

Inventive Principle:

Principle #16Partial or excessive action

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 system effectively balances charge and monitors temperature across energy storage units, preventing cell abuse, maximizing cycle life, and ensuring efficient energy use by maintaining consistent voltage levels and detecting anomalies early.

Implementation Method 1

Temperature sensors and internal estimation methods to ensure safe operation and equalization of cell voltages

Methodology Applied

Scientific EffectTemperature sensing:

Implementation Method 2

A method and system for monitoring temperature in a plurality of energy storage units

Methodology Applied

Scientific EffectThermal energy detection:

Data Source

PatentUS8306771B2Cell based temperature monitoring

Publication Date: 2012.11.06 TEXAS INSTRUMENTS NORTHERN VIRGINIA INC

AI summary

A system and method for measuring a temperature in at least one energy storage unit. The system includes at least one temperature sensor thermally coupled to the at least one energy storage unit, and a battery management controller in communication with the at least one temperature sensor. The battery management controller is configured to process a temperature of the at least one energy storage unit to obtain an internal temperature in the at least one energy storage unit.