Secondary Battery Swelling Sensor With Incised Film Bridges
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Solution Overview
Problem
Secondary batteries can experience swelling due to overcharging, over-discharging, internal or external shorts, and external heat, leading to potential damage and fire risks, as existing technologies lack effective means to detect and prevent such swelling in real-time.
Innovation Solution
A secondary battery design incorporating a swelling sensor with a base film featuring incised portions and bridges, and a conductive line that is damaged when the battery case swells, triggering an alarm to prevent further charging or discharging and reducing fire risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a swelling sensor with incised portions and bridges is added to detect case swelling, then safety and early detection capability are improved, but device complexity increases
Solution Approach 1:
The base film is divided into multiple incised portions that create separate bridges. When swelling occurs, these bridges independently deform and break at different points, providing segmented detection zones that enhance reliability while maintaining a relatively simple overall structure.
Solution Approach 2:
The conductive line serves as an intermediary element that translates mechanical deformation of the base film bridges into electrical signals. This mediator converts physical swelling detection into an easily detectable electrical change, improving safety without requiring complex mechanical sensing mechanisms.
2Measurement precision
If the conductive line is placed on bridges to detect swelling through bridge damage, then detection precision is improved, but manufacturing precision requirements increase
Solution Approach 1:
The incised portions are pre-formed in the base film during manufacturing, creating predetermined weak points and bridges. This preliminary action ensures that the swelling detection mechanism is pre-configured with known detection points, improving detection precision while allowing for standard manufacturing tolerances.
Solution Approach 2:
The base film has different structural qualities at different locations: the incised portions create localized weak bridges that are more susceptible to swelling-induced damage, while other areas remain intact. This local quality differentiation enables precise swelling detection at specific critical points without requiring the entire structure to meet high precision standards.
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 swelling sensor effectively detects case swelling at an early stage, preventing damage to external devices and reducing the risk of fire by discontinuing charging or discharging processes, thus ensuring safer battery operation.
Implementation Method 1
When the case swells, the base film is transformed, at least one of the bridges may be damaged, and the conductive line may be incised
Data Source
AI summary
A secondary battery comprising an electrode assembly including a positive electrode, a negative electrode, and a separator, a case accommodating and sealing the electrode assembly, and a swelling sensor on an outer side of the case, wherein the swelling sensor includes a base film on which a plurality of incised portions are disposed, and a conductive line on the base film passing among the plurality of incised portions.