Sealed Battery Pack Pressure Switch for Parked Cell Fault Detection
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Solution Overview
Problem
Existing battery pack detection systems for electric vehicles face challenges in accurately detecting cell abnormalities with a small number of detection devices, particularly when the vehicle is parked, as the pressure rise due to cell abnormalities is transient and often undetectable by conventional pressure sensors.
Innovation Solution
A battery pack with a substantially sealed structure and a non-resettable pressure switch connected to a controller via a signal line, which changes state irreversibly when internal pressure exceeds a threshold, allowing for high-accuracy detection of cell abnormalities with a minimal number of detection devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pressure sensor is used to detect cell abnormalities by monitoring pressure changes, then detection accuracy can be improved, but the system load increases and the detection cycle must be shorter than the transient pressure rise period (1- several seconds)
Solution Approach 1:
The patent employs a non-resettable pressure switch that undergoes a one-time irreversible state change when pressure exceeds the threshold. This disposable detection mechanism captures the transient pressure event without requiring continuous monitoring or system activation, thereby reducing system load while maintaining detection accuracy.
Solution Approach 2:
The pressure switch is pre-configured with a predetermined threshold value before deployment. When the transient pressure event occurs, the switch automatically activates at the precise threshold level without requiring real-time system intervention or continuous scanning, enabling detection even when the system is in shutdown or standby mode.
2Use of energy by moving object
If the detection system is shut down or in standby mode to reduce power consumption, then energy efficiency improves, but the ability to detect transient pressure changes in real-time is lost
Solution Approach 1:
The pressure switch operates autonomously without requiring system power or controller activation. It automatically detects and responds to pressure threshold exceedances on its own, even when the detection system is shut down or in standby mode, thereby maintaining reliability while minimizing energy consumption.
Solution Approach 2:
The non-resettable pressure switch provides a low-cost, passive detection solution that does not require continuous system operation. Its one-time irreversible activation captures transient events without demanding ongoing power supply, enabling the system to remain in low-power states while preserving detection capability.
3Measurement precision
If temperature measurement is used to detect cell abnormalities with high accuracy, then detection precision improves, but the number of required sensors and cost increase significantly
Solution Approach 1:
The patent merges the detection function into a single pressure switch that monitors the collective pressure state of the battery pack. This consolidates multiple potential temperature sensors into one pressure-based detection device, reducing the quantity of components while maintaining the ability to detect cell abnormalities through pressure changes caused by gas ejection.
Solution Approach 2:
The pressure switch serves as a universal detection mechanism for the entire battery pack, replacing the need for individual temperature sensors on each cell. A single pressure switch can detect abnormalities across multiple cells by monitoring the overall pressure change, providing multi-functionality with a single component.
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 real-time detection of cell abnormalities even when the system is in a shutdown or standby state, reducing the load on the detection system and ensuring safety and convenience by triggering appropriate responses, such as cooling the cells.
Implementation Method 1
a non-resettable pressure switch that is connected to a controller by a signal line. The pressure switch changes irreversibly from a significant state to a non-significant state when a pressure in the battery pack is greater than a predetermined pressure threshold value
Data Source
AI summary
Battery pack (10) having a substantially sealed structure includes a plurality of cells (11-16) each having an opened portion provided in order to discharge an internal gas when an internal pressure rises. Non-resettable pressure switch (30, 31) that is connected to controller (50) by a signal line. The pressure switch changes irreversibly from a significant state to a non-significant state when a pressure in battery pack (10) is greater than a predetermined pressure threshold value.