Embedded Battery Cell Sensors for Real-Time SOH Monitoring
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Solution Overview
Problem
Conventional battery management systems (BMS) lack real-time monitoring of individual cell-level parameters such as temperature, state of charge (SOC), and state of health (SOH), which is critical for ensuring operational safety and efficiency, especially in applications like aerospace where batteries are exposed to varying environmental conditions and high stress.
Innovation Solution
The development of 3D printed sensing systems embedded inside battery cells, using techniques like nanoscribe and aerosol jet technology, to create fiber Bragg grating sensors on dielectric separators for real-time monitoring of temperature, pressure, strain, and other parameters, enabling comprehensive and robust battery management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional BMS sampling external temperature and electrical properties is used, then manufacturing is simple, but measurement precision and reliability are insufficient due to lack of cell-level monitoring
Solution Approach 1:
The sensor is embedded within the battery cell structure itself, specifically integrated into the separator layer. This nesting approach allows the sensor to be positioned at the cell-level for accurate monitoring while remaining part of the battery's internal architecture, thus improving measurement precision without significantly increasing overall device complexity
Solution Approach 2:
The patent introduces an intermediary sensor system that bridges the gap between conventional external monitoring and true cell-level monitoring. The sensor embedded in the separator acts as a mediator, providing direct access to cell-level parameters (temperature, strain, pressure) without requiring complex external sampling systems
2Reliability
If sensors are embedded in battery cells for real-time monitoring, then reliability improves, but manufacturing complexity increases
Solution Approach 1:
The sensor is embedded in the separator during the battery manufacturing process itself, before the cell is assembled and sealed. This preliminary action ensures the sensor is already in position when the battery is completed, eliminating the need for post-assembly sensor installation and reducing manufacturing complexity
Solution Approach 2:
The sensor functionality is merged with the separator component. Instead of adding a separate sensor assembly to the battery, the sensing elements are integrated directly into the separator material, combining two functions (separation and sensing) into a single component, thereby improving reliability without significantly increasing manufacturing complexity
3Loss of information
If comprehensive cell-level monitoring is implemented, then loss of information is reduced, but device complexity increases
Solution Approach 1:
The embedded sensor system is designed to monitor multiple parameters (temperature, strain, pressure) simultaneously using a single integrated sensor platform. This multi-functionality reduces the need for multiple separate sensors and data collection systems, thereby reducing loss of information without proportionally increasing device complexity
Solution Approach 2:
The monitoring system is segmented into modular components: the embedded sensor in the separator, the data collection electronics, and the analysis system. This segmentation allows for scalable implementation where cell-level monitoring can be added without requiring complete system redesign, thus reducing information loss while managing complexity
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 allows for real-time, individual cell-level monitoring, reducing the likelihood of catastrophic failures, simplifying manufacturing, and maintaining negligible weight addition to the battery pack, while providing more accurate and comprehensive data for battery health assessment.
Implementation Method 1
create fiber Bragg grating sensors on dielectric separators for real-time monitoring of temperature, pressure, strain, and other parameters
Data Source
AI summary
The disclosed principles provide techniques for 3D fabrication of sensing systems embedded inside battery cells and provide cell parameter data for a comprehensive and robust battery management system. The disclosed principles provide online and real-time monitoring battery state-of-health down to the individual cell level of each battery using embedded sensors on one or more of the internal layers of a cell, such as the dielectric separators found in such battery cells. The implementation of the disclosed principles in individual battery cells therefore provides an increased likelihood to mitigate catastrophic failures in batteries. In addition, the disclosed fabrication processes for printing sensors directly on one or more of the components or layers within each individual battery cell significantly reduce manufacturing steps required by conventional battery management systems. The disclosed principles also provided for a unique silica-based ink for use in the 3D printing of such embedded cell sensing components.