Battery Cell Vent Cap Rupture Detection Using Multi-Sensor Monitoring
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Solution Overview
Problem
Current systems for electric vehicles (EVs) lack effective early detection methods for vent cap rupture and thermal runaway events in battery cells, which can lead to safety and operational issues.
Innovation Solution
A system comprising sensors (gas, temperature, pressure, wire, eddy current, and strain gauge sensors) adjacent to the vent cap to detect parameter changes indicative of rupture, with a controller comparing these parameters to predetermined thresholds to identify and respond to vent cap ruptures and potential thermal runaway events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensor types (gas, temperature, pressure, wire, eddy current, strain gauge) are deployed to detect vent cap rupture parameters, then detection precision and reliability are improved, but device complexity increases
Solution Approach 1:
The patent divides the detection system into multiple independent sensor modules, each responsible for detecting specific parameters (gas concentration, temperature, pressure, structural deformation). This segmentation allows each sensor to specialize in one aspect of rupture detection, improving overall measurement precision while enabling modular system design that manages complexity through functional decomposition
Solution Approach 2:
The controller integrates multiple detection functions into a single system, processing data from all sensor types to comprehensively determine vent cap rupture status. This multi-functionality approach consolidates the complex detection tasks into one centralized unit, improving detection reliability while managing system complexity through unified control logic
2Reliability
If a wire sensor traversing the vent cap is used to detect rupture, then detection reliability is improved, but ease of manufacture deteriorates due to additional installation complexity
Solution Approach 1:
The wire sensor is pre-installed and positioned to traverse the vent cap during battery assembly, establishing the detection mechanism before the vent cap is sealed. This preliminary action ensures the sensor is in place to detect rupture events, improving reliability while allowing the wire to be integrated into the manufacturing process rather than added as a separate post-assembly step
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 and precise detection of vent cap ruptures and thermal runaway events, allowing for timely diagnostics and mitigation actions to improve safety and operational efficiency of EV battery systems.
Implementation Method 1
The first sensor comprises a gas sensor configured to sense a concentration of one or more gases exiting the vent cap. The one or more gases are selected from a group consisting of molecular hydrogen (H2), carbon monoxide (CO), carbon dioxide (CO2), and ethylene.
Implementation Method 2
The first sensor comprises a temperature sensor configured to sense a temperature of vent gases exiting the vent cap.
Implementation Method 3
The first sensor comprises a pressure sensor configured to sense pressure of vent gases exiting the vent cap.
Implementation Method 4
The first sensor comprises an eddy current sensor.
Implementation Method 5
The first sensor comprises a strain gauge sensor. The strain gauge sensor includes a flexible substrate and a conductive layer arranged on the flexible substrate in a predetermined pattern.
Data Source
AI summary
A system for detecting bulging or rupturing of a vent cap includes a battery cell including a rigid enclosure, first and second terminals, and a vent cap. A first sensor is arranged adjacent to the vent cap and configured to sense a parameter affected by rupturing of the vent cap. A controller is configured to compare the parameter to a predetermined parameter and to detect rupturing of the vent cap in response to the comparison.