Pouch Cell Temperature Sensing Array for Hot-Spot Detection
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Solution Overview
Problem
Battery systems, particularly those with Li-ion pouch cells, lack effective temperature monitoring capabilities, leading to potential thermal runaway issues due to the inability to individually monitor and control the temperature of each cell, which increases costs and weight when using traditional sensing devices like thermocouples.
Innovation Solution
A temperature sensing array is implemented on each battery cell, comprising a conducting strip with temperature sensors, including low melting point alloy traces and components like resistance thermometers or thermistors, distributed across the cell's surface, which changes output current in response to temperature variations, allowing for precise temperature monitoring and disconnection of overheated cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional sensing devices like thermocouples are used to monitor battery cell temperature, then temperature monitoring capability is improved, but cost and weight increase
Solution Approach 1:
The patent combines multiple temperature sensing functions into a single integrated temperature sensing array that can monitor multiple locations on a battery cell simultaneously. The array integrates multiple temperature sensors (thermistors, diodes, or resistance thermometers) with a common conducting strip, eliminating the need for multiple separate thermocouple devices and their associated wiring harnesses, thereby reducing overall system weight while maintaining comprehensive temperature monitoring capability.
Solution Approach 2:
The temperature sensing array serves multiple functions: it monitors temperature at multiple discrete locations across the battery cell surface, provides thermal runaway protection, and enables precise localization of hot spots. This multi-functional approach replaces what would traditionally require multiple separate sensing devices, reducing weight while improving monitoring comprehensiveness.
2Measurement precision
If traditional sensing devices like thermocouples are used to monitor battery cell temperature, then temperature monitoring capability is improved, but cost increases
Solution Approach 1:
The patent combines multiple temperature sensing functions into a single integrated temperature sensing array that can monitor multiple locations on a battery cell simultaneously. The array integrates multiple temperature sensors (thermistors, diodes, or resistance thermometers) with a common conducting strip, eliminating the need for multiple separate thermocouple devices and their associated wiring harnesses, thereby reducing overall system weight while maintaining comprehensive temperature monitoring capability.
Solution Approach 2:
The patent employs inexpensive temperature sensor elements (such as thermistors, diodes, or resistance thermometers) that can be mass-produced at low cost. These sensors are integrated into a simple array structure with a common conducting strip, avoiding the need for expensive thermocouple assemblies. The simplified design and use of low-cost sensor technologies significantly reduce manufacturing costs while providing adequate temperature monitoring functionality.
3Measurement precision
If temperature sensors are distributed across the battery cell surface, then temperature monitoring precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple temperature sensing functions into a single integrated temperature sensing array that can monitor multiple locations on a battery cell simultaneously. The array integrates multiple temperature sensors (thermistors, diodes, or resistance thermometers) with a common conducting strip, eliminating the need for multiple separate thermocouple devices and their associated wiring harnesses, thereby reducing overall system weight while maintaining comprehensive temperature monitoring capability.
Solution Approach 2:
The temperature sensing array serves multiple functions: it monitors temperature at multiple discrete locations across the battery cell surface, provides thermal runaway protection, and enables precise localization of hot spots. This multi-functional approach replaces what would traditionally require multiple separate sensing devices, reducing weight while improving monitoring comprehensiveness.
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 enables effective temperature monitoring and control of individual battery cells, preventing thermal runaway by disconnecting overheated cells, thus enhancing safety and reducing costs and weight compared to traditional sensing methods.
Implementation Method 1
each of the plurality of temperature sensors has at least one characteristic that varies in accordance with temperature, where the plurality of temperature sensors is distributed in different locations across the surface of the battery cell, and where an output current of the temperature sensing array varies in accordance with a change in temperature
Implementation Method 2
the temperature sensors each include a plurality of low melting point alloy (LMPA) traces connected in parallel with each other and in series with the conducting strip
Data Source
AI summary
A battery system includes: a battery cell; and a temperature sensing array disposed on a surface of the battery cell, the temperature sensing array including: a conducting strip; and a plurality of temperature sensors connected in series with the conducting strip such that current flowing through the conducting strip flows through each of the temperature sensors, where each of the plurality of temperature sensors has at least one characteristic that varies in accordance with temperature, where the plurality of temperature sensors is distributed in different locations across the surface of the battery cell, and where an output current of the temperature sensing array varies in accordance with a change in temperature in any of the different locations.