Embedded Thermal Sensing Pad for Internal Battery Hotspot Detection
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Solution Overview
Problem
Conventional battery management systems rely on external temperature sensors that are ineffective in detecting localized temperature spikes within lithium batteries, leading to delayed detection and inadequate response to thermal runaway, which compromises safety and reliability.
Innovation Solution
Integration of an electrolyte-resistant thermal sensing pad with multiple temperature sensors within the battery structure, coupled with an integrated circuit board and application software for real-time internal temperature monitoring and analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external temperature sensors are used to monitor battery temperature, then the device complexity is reduced and ease of manufacture is improved, but the measurement precision of internal temperature is insufficient and thermal runaway detection is delayed
Solution Approach 1:
The temperature sensor is embedded within the battery cell structure, specifically integrated into the separator layer. This nesting approach allows the sensor to be positioned inside the battery without significantly increasing external complexity, while achieving direct internal temperature measurement capability that resolves the contradiction between measurement precision and device complexity.
Solution Approach 2:
The patent introduces a specialized sensor structure that acts as an intermediary between the battery's internal thermal conditions and the external monitoring system. The sensor embedded in the separator provides direct thermal coupling to internal hotspots while maintaining electrical isolation and chemical resistance, enabling precise internal temperature detection without complicating the overall battery architecture.
2Reliability
If multiple temperature sensors are integrated within the battery cell, then the reliability of thermal runaway detection is improved, but the manufacturing precision requirements increase and ease of manufacture deteriorates
Solution Approach 1:
The separator layer serves multiple functions: it maintains battery structure, enables ion transport, and now also hosts the temperature sensor. By integrating the sensing function into the existing separator structure, the patent achieves multi-functionality that improves detection reliability while avoiding the need for separate sensor mounting structures, thereby reducing manufacturing precision requirements.
Solution Approach 2:
The patent changes the physical and chemical parameters of the sensor encapsulation material to ensure compatibility with the battery environment. The sensor is encapsulated in a material that provides thermal coupling, electrical insulation, and chemical resistance to electrolyte, allowing reliable operation without requiring ultra-precise placement or additional protective structures.
3Measurement precision
If temperature sensors are placed deep within the battery interior, then the measurement precision of localized temperature spikes is improved, but the device complexity increases and ease of operation deteriorates
Solution Approach 1:
The temperature sensor is pre-integrated into the separator layer during battery manufacturing, before the battery is assembled and sealed. This preliminary action ensures the sensor is already in its optimal position for detecting internal temperature spikes, eliminating the need for complex post-assembly installation procedures and improving ease of operation.
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 early detection of thermal anomalies, enhancing safety and performance by allowing timely intervention to prevent thermal runaway and improving diagnostic precision.
Implementation Method 1
a thermal sensing pad embedded within the battery cell, the thermal sensing pad comprising a plurality of temperature sensors disposed at different internal positions within the battery cell
Data Source
AI summary
A rechargeable battery system is provided. The rechargeable battery system comprises: a battery cell having a laminated housing enclosing electrolyte and electrode stacks; a thermal sensing pad embedded within the battery cell, the thermal sensing pad comprising a plurality of temperature sensors disposed at different internal positions within the battery cell, each temperature sensor encapsulated in an electrolyte-resistant material; an integrated circuit board electrically coupled with the thermal sensing pad, the integrated circuit board configured to: (a) receive sensor signals from the temperature sensors; (b) convert the sensor signals into digital temperature data; and (c) transmit the digital temperature data to a battery management system. The battery management system is configured to analyze the digital temperature data to assess internal temperature conditions of the battery cell.