Heat Transfer Plate Monitoring for Early Battery Thermal Runaway Detection
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Solution Overview
Problem
There is a need for methods and systems to detect conditions that may lead to excessive temperatures in a rechargeable energy storage system (RESS), including the detection of thermal runaway events, to enable timely mitigation efforts.
Innovation Solution
A monitoring system for a multi-cell RESS that includes sensors to monitor heat transfer plates thermally coupled to the battery cells. The system uses a controller with an instruction set to detect thermal runaway events by monitoring parameters such as wave attenuation, temperature, or impedance of the heat transfer plates, and communicates the event to a battery controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional temperature sensors are used to monitor battery cells, then the system can detect thermal conditions, but the response time is delayed and cannot detect early signs of thermal runaway
Solution Approach 1:
The patent introduces heat transfer plates as intermediary components that are thermally coupled to battery cells. These plates serve as mediators between the battery cells and the temperature sensors, allowing early detection of thermal runaway events before they affect the battery cells themselves. The heat transfer plates respond faster to thermal changes, providing earlier warning signals.
Solution Approach 2:
The system performs preliminary thermal monitoring by placing heat transfer plates in thermal contact with battery cells before thermal runaway occurs. This allows the system to detect early thermal anomalies and initiate mitigation actions before the full thermal runaway event develops, improving both detection accuracy and response time.
2Measurement precision
If multiple sensors are placed directly on battery cells to improve detection accuracy, then thermal runaway can be detected earlier, but the system complexity and cost increase
Solution Approach 1:
Instead of placing multiple sensors directly on battery cells, the patent uses heat transfer plates as intermediaries that can be monitored by fewer sensors. The heat transfer plates aggregate thermal information from multiple battery cells, allowing a single sensor to monitor multiple cells through the plate, thereby reducing system complexity while maintaining detection accuracy.
Solution Approach 2:
The heat transfer plates serve multiple functions: they act as thermal conduits from battery cells, serve as mounting surfaces for sensors, and provide structural support. This multi-functionality reduces the number of separate components needed, simplifying the overall system while maintaining effective thermal monitoring.
3Reliability
If heat transfer plates are thermally coupled to battery cells to monitor thermal conditions, then thermal runaway detection is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent divides the battery pack into modular sections with individual heat transfer plates for each cell or cell group. This segmentation allows for standardized manufacturing of individual plate-cell assemblies that can be easily replicated and assembled, reducing overall manufacturing complexity while improving thermal monitoring reliability.
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 detects thermal runaway events in the RESS, allowing for timely mitigation actions to prevent damage and ensure safe operation.
Implementation Method 1
an ultrasonic sensor that is arranged to monitor a wave attenuation in the heat transfer plate, wherein the wave attenuation correlates to a temperature in the heat transfer plate
Implementation Method 2
heat transfer plates thermally coupled to the plurality of battery cells
Data Source
AI summary
A monitoring system for a multi-cell rechargeable energy storage system (RESS) that includes a plurality of battery cells is described. The monitoring system includes a sensor that is arranged to monitor one or multiple heat transfer plates thermally coupled to the plurality of battery cells, a controller is in communication with the sensor. The controller including an instruction set that is executable to monitor, via the sensor, a parameter of the heat transfer plate and detect a thermal runaway event when the parameter of the heat transfer plate exceeds a threshold. The thermal runaway event is communicated to a battery controller.