A SYSTEM FOR DETECTING AND EJECTING AN OVERHEATED BATTERY CELL OF AN ELECTRIC VEHICLE

Abstract

ABSTRACT A SYSTEM FOR DETECTING AND EJECTING AN OVERHEATED BATTERY CELL OF AN ELECTRIC VEHICLE The present disclosure discloses a system for detecting and ejecting an overheated battery cell(104) of an electric vehicle. The system(100) comprises a battery pack(102) includes a top plate(102a) and a bottom plate(102b); a plurality of battery cells(104) integrated inside the battery pack(102) in an electric circuit; a heat sensitive strips(106) detect overheating of the battery cell(104); a plurality of button switches(108) formed at the end of the heat-sensitive strips(106) and get triggered upon expansion of the heat sensitive strip(106); a thermally sensitive membrane(110) placed underneath each of plurality of battery cells(104) melt when exposed to the heat beyond the threshold temperature; a microprocessor(112) connects to plurality of button switches(108) receive the electrical signal from the heat sensitive strips(106) and process the electric signal and identify the overheated battery cell(104); a communication interface(114) connect to microprocessor(112) to transmit the location of overheated battery cell(104) on a display module(116) of electric vehicle.

Specification

Description:FIELD
The present disclosure generally relates to the field of battery cells. More particularly, the present disclosure relates to a system and a method for detecting and ejecting an overheated battery cell of an electric vehicle.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
The traditional battery safety systems primarily focus on thermal management at the pack level, employing cooling mechanisms, temperature sensors, and battery management systems (BMS) to detect and prevent thermal runaway. The traditional system typically relies on active cooling techniques, such as liquid or air cooling, to dissipate heat and maintain the battery's operational temperature within safe limits. Sensors and complex electronic monitoring continuously track the battery's overall temperature and performance parameters to identify potential failure risks. However, the safety measures are predominantly configured to intervene at the macro level of the entire battery pack rather than addressing thermal anomalies or faults at the individual cell level. Consequently, the traditional system aims to prevent the propagation of thermal runaway through system-wide interventions.
Despite their benefits, the traditional system of battery safety faces several limitations. The foremost issue associated with the traditional system is that the traditional system lacks precision in detecting failures at the individual cell level, as these systems often monitor temperature at the pack level only. Furthermore, the traditional systems are energy-intensive, requiring continuous power to operate the monitoring components and cooling systems, which increases operational costs. These systems may also involve moving parts and complex electronic assemblies, adding to the expense and introducing additional potential failure points. Importantly, when a fault is detected, these systems may trigger a complete shutdown of the battery pack, rendering the system inoperable, even if only a single cell is affected. Such inefficiencies compromise the operational continuity and safety of the battery systems, highlighting the need for more targeted and energy-efficient solutions.
Therefore, there is felt a need for a system for detecting and ejecting an overheated battery cell of an electric vehicle that alleviates the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide a system for detecting and ejecting an overheated battery cell of an electric vehicle.
Another object of the present disclosure is to provide a system that enables easy ejection and disconnection of individual cells.
Still another object of the present disclosure is to provide a system that identifies the exact overheating cells within a battery pack without the need for complex electronic sensors.
Yet another object of the present disclosure is to provide a system that monitors cell temperature that does not require constant power.
Still another object of the present disclosure is to provide a system that automatically ejects a damaged or overheating cell.
Yet another object of the present disclosure is to provide a system that significantly reduces operational costs by eliminating the need for complex electronic sensors and cooling mechanisms.
Still another object of the present disclosure is to provide a system that ensures the damage cell does not affect the entire battery pack.
Yet another object of the present disclosure is to provide a system that ensures safety without compromising the functionality of other components.
Still another object of the present disclosure is to provide a system that improves the efficiency of energy storage systems.
Yet another object of the present disclosure is to provide a system that promotes sustainable use of energy storage technology.
Still another object of the present disclosure is to provide a method for detecting and ejecting an overheated battery cell of an electric vehicle.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a system for detecting and ejecting an overheated battery cell of an electric vehicle. The system comprises a battery pack, a plurality of battery cells, heat-sensitive strips, a plurality of button switches, a thermally sensitive membrane, a microprocessor, and a communication interface.
The battery pack includes a top plate and a bottom plate.
The plurality of battery cells integrated inside the battery pack in an electric circuit connection to power the electric vehicle.
The heat-sensitive strips are placed across the plurality of battery cells and electrically connected to the top plate of the battery pack, each of the heat-sensitive strips is configured to detect overheating of a battery cell by expanding when exposed to heat above a threshold temperature, the expansion triggering an electrical signal.
The plurality of button switches formed at the end of the heat-sensitive strip and each of the button switches is configured to be triggered upon expansion of the heat-sensitive strip and disconnect electrical connection with the overheated battery cell.
The thermally sensitive membrane is connected to the bottom plate and placed underneath each of the plurality of battery cells and is configured to melt when exposed to heat beyond the threshold temperature, causing the overheated battery cell to be mechanically ejected from the battery pack.
The microprocessor communicatively connected to the plurality of button switches to:
• receive the electrical signal from the heat-sensitive strips; and
• process the electrical signal to identify the overheated battery cell from the battery pack.
The communication interface is communicatively connected to the microprocessor to:
• transmit the location of the overheated battery cell on a display module of the electric vehicle for real-time alerts.
In an embodiment, the threshold temperature is 75°C.
In an embodiment, the microprocessor is further configured to continuously monitor the electrical signals from the heat-sensitive strips.
In an embodiment, the thermally sensitive membrane is a paraffin wax configured to melt at the threshold temperature to facilitate the ejection of the overheated battery cell.
In an embodiment of, heat-sensitive strips are ceramic strips placed in a matrix pattern across the plurality of battery cells and configured to expand when exposed to heat so as to trigger the button switches by expansion.
In an embodiment, the heat-sensitive strips are composed of zirconia.
In an embodiment, the bottom plate is configured with breakable links and each link is slightly cracked and configured to fully break when the overheated battery cell is ejected, thereby disconnecting the overheated battery cell from the electric circuit.
In an embodiment, the display module is a vehicle's dashboard for the electric vehicle to receive the alert from the microprocessor.
In an embodiment, the vehicle's dashboard includes a visual and audio alert mechanism triggered by the microprocessor to notify a driver in real-time of the exact location and status of the overheated battery cell.
In an embodiment, the microprocessor is further configured to record multiple overheated events, allowing the ejection of more than one overheated battery cell in the event of simultaneous thermal runaway occurrences.
In an embodiment, the system operates in a passive state, requiring no continuous external power supply for the heat-sensitive strips.
The present disclosure further envisages a method for detecting and ejecting an overheated battery cell of an electric vehicle. The method includes the following steps:
• monitoring by heat sensitive strips, overheating of each of a plurality of battery cells of a battery pack;
• detecting, by the heat sensitive strips, a overheated battery cell by expanding when exposed to heat above a threshold temperature;
• triggering, by the heat-sensitive strips, an electrical signal upon expansion of a heat-sensitive strip in response to overheating;
• disconnecting, by a button switch, an electrical connection of the overheated battery cell upon being triggered by the expansion of the heat-sensitive strip;
• melting a thermally-sensitive membrane placed underneath the overheated battery cell, when exposed to the heat beyond the threshold temperature, thereby causing the overheated battery cell to be mechanically ejected from the battery pack;
• receiving the electrical signal from the heat-sensitive strip by a microprocessor;
• processing the electrical signal by the microprocessor to identify a location of the overheated battery cell of the battery pack; and
• transmitting, by a communication interface, the location of the overheated battery cell to a display module for real-time alerts.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A system and a method for detecting and ejecting an overheated battery cell of an electric vehicle of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a block diagram of a system for detecting and ejecting an overheated battery cell of an electric vehicle in accordance with the present disclosure;
Figure 2A and Figure 2B illustrate a flow chart depicting the steps involved in a method for detecting and ejecting an overheated battery cell of an electric vehicle in accordance with an embodiment of the present disclosure;
Figure 3 illustrates a flow of detecting the temperature of overheated battery cell in accordance with an embodiment of the present disclosure;
Figure 4 illustrates a battery pack layout with a grid setup in accordance with an embodiment of the present disclosure;
Figure 5 illustrates a top view of cell connection in accordance with an embodiment of the present disclosure;
Figure 6 illustrates a structural layout of the top plate and the bottom plates of the battery pack in accordance with an embodiment of the present disclosure;
Figure 7 illustrates a top and bottom plate with embedded ceramic heat sensitive strips and breakable cell connections in accordance with an embodiment of the present disclosure;
Figure 8 illustrates a detailed view of the ceramic heat sensitive strip layout, button switches, and thermally sensitive membrane with breakable links in accordance with an embodiment of the present disclosure; and
Figure 9 illustrates a side view of the battery pack compartment with ejection and detection systems in accordance with an embodiment of the present disclosure;
LIST OF REFERENCE NUMERALS
100 - System
102 - Battery Pack
102a - Top Plate
102b - Bottom Plate
104 - Battery Cell
106 - Heat Sensitive Strips
108 - Button Switch
110 - Thermally Sensitive Membrane
112 - Microprocessor
114 - Communication interface
116 - Display Module
118 - Breakable links
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details, are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a," "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "including," and "having," are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being "engaged to," "connected to," or "coupled to" another element, it may be directly engaged, connected, or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Conventional systems for detecting and ejecting faulty battery cells come with several drawbacks. One of the primary limitations is their inability to precisely identify failures at the level of individual cells, as most systems only monitor temperature at the pack level. Moreover, these systems tend to be energy-demanding, requiring a constant supply of power to operate monitoring devices and cooling mechanisms, which results in higher operational costs. Another concern is the reliance on complex electronic components and mechanical parts, which not only increases the system's expense but also introduces more points of potential failure. When a fault is detected, traditional systems often initiate a complete battery pack shutdown, even if the issue lies with just one cell, causing unnecessary disruption. These issues highlighted the need for more advanced, targeted, and energy-efficient solutions capable of addressing individual cell failures without compromising overall system functionality.
To address the issues of the existing systems and methods, the present disclosure envisages a system (hereinafter referred to as "system 100") for detecting and ejecting an overheated battery cell 104 of an electric vehicle and a method (hereinafter referred to as "method 200") for detecting and ejecting an overheated battery cell 104 of an electric vehicle. The system 100 will now be described with reference to Figure 1 and the method 200 will be described with reference to Figure 2A and Figure 2B.
Referring to Figure 1, the system 100 comprises a battery pack 102, a plurality of battery cells 104, heat sensitive strips 106, a plurality of button switches 108, a thermally-sensitive membrane 110, a microprocessor 112, and a communication interface 114.
The battery pack 102 includes a top plate 102a and a bottom plate 102b.
In an embodiment, the bottom plate 102b is configured with a breakable link 118, and each link is slightly cracked and configured to fully break when the overheated battery cell 104 is ejected, thereby disconnecting the overheated battery cell 104 from the electric circuit. The top plate 102a is configured with an electrical connection and integrated with the heat-sensitive strips 106.
The plurality of battery cells 104 is integrated inside the battery pack 102 in an electric circuit connection to power the electric vehicle.
The heat-sensitive strips 106 were placed across the plurality of battery cells 104 and electrically connected to the top plate 102a of the battery pack 102. Each of the heat-sensitive strips 106 is configured to detect overheating of the battery cell 104 when exposed to heat above a threshold temperature, the overheated battery cell 104 expands and this expansion triggers an electrical signal.
The plurality of button switch 108 is formed at the end of the heat-sensitive strip 106 and each of the button switch 108 is configured to be triggered upon expansion of the heat-sensitive strip 106 and disconnect electrical connection with the overheated battery cell 104.
In an embodiment, the plurality of button switches 108 triggered upon the expansion of the heat-sensitive strips 106 when the specific battery cell 104 overheats. The heat-sensitive strip 106 of a specific row and column expands and triggers the button switch 108 of a specific row and column to identify the exact cell in danger.
In an embodiment, the heat-sensitive strips 106 are ceramic strips placed in a matrix pattern across the plurality of battery cells 104 and are configured to expand when exposed to heat so as to trigger the button switches 108 by expansion. The heat-sensitive strip 106 is composed of zirconia and is a ceramic strip, that expands when exposed to heat, placed in a matrix pattern across the battery cells 104. When specific cells of the plurality of battery cells 104 get overheated, the heat-sensitive strip 106 of that row and column expands.
In an embodiment, the heat sensitive strips 106 are placed over individual battery cells 104, and the heat sensitive strips 106 are configured to expand when exposed to heat above a threshold temperature. The heat sensitive strips 106 expand enough to press or trigger the button switch 108. The heat-sensitive strips 106 activate or begin to expand only at the desired overheating threshold temperature.
The thermally-sensitive membrane 110 connected to the bottom plate 102b and placed underneath each of the plurality of battery cells 104. The thermally sensitive membrane 110 is configured to melt when exposed to heat beyond the threshold temperature, causing the overheated battery cell 104 to be mechanically ejected from the battery pack 102.
In an embodiment, the thermally sensitive membrane 110 is a paraffin wax configured to melt at the threshold temperature to facilitate the ejection of the overheated battery cell 104. The threshold temperature is 75°C. The battery cell 104 overheats, and the thermally sensitive membrane 110 beneath the battery cell 104 melts. The weight of the cell breaks the breakable link 118, allowing the cell to disconnect and pop out of the battery pack 102.
In an embodiment, the thermally sensitive membrane 110 beneath the overheated battery cell 104 melts when exposed to heat beyond the threshold temperature. The weight of the overheated battery cell 104 breaks the breakable link 118 or pre-cracked connection beneath the overheated battery cell 104.
The microprocessor 112 communicatively connected to the plurality of button switches 108 to receive the electric signal from the heat sensitive strips 106 and process the electrical signal to identify the overheated battery cell 104 from the battery pack 102.
In an embodiment, the microprocessor 112 is further configured to record multiple overheating events, allowing the ejection of more than one overheated battery cell 104 in the event of simultaneous thermal runaway occurrences, and is configured to continuously monitor the electrical signals from the heat sensitive strips 106.
The communication interface 114 communicatively connects to the microprocessor 112 to transmit the location of the overheated battery cell 104 on a display module 116 of the electric vehicle for real-time alerts.
In an embodiment, the display module 116 is a vehicle dashboard of the electric vehicle to receive the alert from the microprocessor 112. The vehicle dashboard includes a visual and audio alert mechanism triggered by the microprocessor 112 to notify a driver in real-time of the exact location and status of the overheated battery cell 104.
The system 100 for detecting and ejecting the overheated battery cell 104 comprises hardware components including one or more processors, memory units, and data storage modules, configured to communicate with the plurality of button switches 108 to receive the electric signal from the heat sensitive strips 106 and process the electrical signal to identify the overheated battery cell 104.
In an embodiment, the system 100 can include one or more processors and may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, logic circuitries, and/or any devices that manipulate data based on operational instructions. Among other capabilities, the one or more processors are configured to fetch and execute computer-readable instructions stored in a memory of the system 100. The memory may store one or more computer-readable instructions or routines, which may be fetched and executed for executing the instructions. The memory may include any non-transitory storage device including, for example, volatile memory such as RAM, or non-volatile memory such as EPROM, flash memory, and the like. The functions of one or more processor(s) may be provided through the use of dedicated hardware as well as hardware capable of executing machine-readable instructions. In other examples, one or more processors may be implemented by electronic circuitry or printed circuit board. One or more processors may be configured to execute functions of various modules of the system 100 such as the plurality of battery cells 104, the plurality of button switches 108, the communication interface 114, and the display module 116.
In an alternative aspect, the memory may be an external data storage device coupled to the system 100 directly or through one or more offline/online data servers.
In an embodiment, the system 100 further comprises the communication interface 114 to receive the location of the overheated battery cell 104 from sources such as databases, APIs, sensors, and the microprocessor 112 which are used by the display module 116 to show the real-time alert of the overheated battery cell 104 on electric vehicles.
The communication interface 114 may include a variety of interfaces, for example, interfaces for data input and output devices, referred to as I/O devices, transceivers, storage devices, and the like. The communication interface 114 may facilitate communication of the system 100 with various devices coupled to the system 100. The communication interface 114 may also provide a communication pathway for one or more components of the system 100. Examples of such components include but are not limited to, processing module(s), the microprocessor 112, and data storage.
The processing modules(s) may be implemented as a combination of hardware and programming (for example, programmable instructions) to implement one or more functionalities of the processing module(s). In the examples described herein, such combinations of hardware and programming may be implemented in several different ways. For example, the programming for the processing module(s) may be processor-executable instructions stored on a non-transitory machine-readable storage medium and the hardware for the processing module(s) may include a processing resource (for example, one or more processors), to execute such instructions. In the present examples, the machine-readable storage medium may store instructions that, when executed by the processing resource, implement the processing module(s). In such examples, the system 100 may include the machine-readable storage medium storing the instructions and the processing resource to execute the instructions, or the machine-readable storage medium may be separate but accessible to the system 100 and the processing resource. In other examples, the processing module(s) may be implemented by electronic circuitry and include the battery pack 102, the plurality of battery cells 104, the heat sensitive strips 106, the plurality of button switches 108, the thermally-sensitive membrane 110, the microprocessor 112, and the communication interface 114.
In an embodiment, the system 100 operates at a passive rate, requiring no continuous external power supply for the heat sensitive strips 106 expansion of the heat sensitive strips 106 is the result of the material physical property and does not require any continuous electric input or external power supply.
In an embodiment, the system 100 includes the heat-sensitive strips 106 that are arranged over the battery cells 104. The heat-sensitive strips 106 are composed of thermally responsive material that expands naturally when exposed to a temperature above a certain threshold. The expansion of the heat sensitive strip 106 is triggered by the battery cell 104 due to thermal runaway, and the expansion of the heat sensitive strip 106 triggers the button switch 108 integrated into the system 100. The triggering of the button switch 108 is a mechanical response to the expansion of the heat-sensitive strips 106, the microprocessor 112 connects to the button switch 108 to receive the electrical signal from the heat sensitive strips 106 and process the electric signal and generate an alert on the vehicle dashboard.
Figure 2A and Figure 2B illustrate a flow chart depicting the steps involved in a method for detecting and ejecting an overheated battery cell 104 of an electric vehicle in accordance with an embodiment of the present disclosure. The order in which method 200 is described is not intended to be construed as a limitation, and any number of the described method steps may be combined in any order to implement method 200, or an alternative method. Furthermore, method 200 may be implemented by processing resource or computing device(s) through any suitable hardware, non-transitory machine-readable medium/instructions, or a combination thereof. The method 200 comprises the following steps:
At step 202, the method 200 includes monitoring by heat-sensitive strips 106, overheating of each of a plurality of battery cells 104 of a battery pack 102.
At step 204, the method 200 includes detecting, by the heat sensitive strips 106, a overheated battery cell 104 by expanding when exposed to heat above a threshold temperature.
At step 206, the method 200 includes triggering, by the heat sensitive strips 106, an electrical signal upon expansion of a heat sensitive strip 106 in response to overheating.
At step 208, the method 200 includes disconnecting, by a button switch 108, an electrical connection of the overheated battery cell 104 upon being triggered by expansion of the heat sensitive strip 106.
At step 210, the method 200 includes melting a thermally-sensitive membrane 110 placed underneath the overheated battery cell 104, when exposed to heat beyond the threshold temperature, thereby causing the overheated battery cell 104 to be mechanically ejected from the battery pack 102.
At step 212, the method 200 includes receiving the electrical signal from the heat-sensitive strip 106 by a microprocessor 112.
At step 214, the method 200 includes processing the electrical signal by the microprocessor 112 to identify a location of the overheated battery cell 104 of the battery pack 102.
At step 216, the method 200 includes transmitting, by a communication interface 114, the location of the overheated battery cell 104 to a display module 116 for real-time alerts.
Figure 3 illustrates a flow of detecting the temperature of the overheated battery cell 104 in accordance with an embodiment of the present disclosure. The process flow of detecting the temperature of the overheated battery cell 104 begins with the battery pack 102 which includes the top plate 102a, the bottom plate 102b, the plurality of battery cells 104 integrated inside the battery pack 102 with mechanical and electric circuits to monitor, detect, and respond to any overheated or thermal runaway events, the heat sensitive strips 106 placed across the plurality of battery cells 104 and electrically connected to the top plate 102a, the button switches 108 formed at the end of the heat-sensitive strips 106. The bottom plate 102b of the battery pack 102 consists of the thermally-sensitive membrane 110 is configured to melt when exposed to heat beyond the threshold temperature.
When a thermal runaway is initiated in one or more battery cell 104 within the battery pack 102, the temperature of the specific battery cell 104 rises uncontrollably due to internal issues such as overcharging, short-circuiting, or excessive heat, as a result, the thermal management system is activated to detect and mitigate the effects of rise temperature increase to prevent damage to the entire battery pack 102. Once the thermal runaway begins, the temperature of the affected or the overheated battery cell 104 crosses a critical threshold, typically set around 75°C. At this point, two critical responses initiate an ejection of the overheated battery cell 104 and alert the driver using the vehicle dashboard. As the specific battery cell 104 temperature exceeds 75°C, the heat sensitive strips 106 placed over the battery cell 104 begin to expand due to their thermally reactive property, as the heat-sensitive strips 106 expand and trigger the button switches 108 placed at the end of each of the heat-sensitive strips 106 and send an electric signal to the microprocessor 112, the actuation of the button switch 108 signals that a cell has exceeded the safety threshold temperature.
The microprocessor 112 processes the electric signal to determine the exact location of the affected battery cell 104 within the battery pack 102, the processed information is communicated to the vehicle dashboard (MID - multi-information display) by the microprocessor 112 of the electric vehicle for real-time alerts.
The thermally sensitive membrane 110 is located beneath the overheated battery cell 104 and connected to the bottom plate 102b. The bottom plate 102b is configured with the breakable link 118 and each link is slightly cracked and configured to fully break when the overheated battery cell 104 is ejected, overheating of the battery cell 104 melts the thermally sensitive membrane 110 beneath, and the weight of the overheated battery cell 104 breaks the breakable link 118, allowing the overheated battery cell 104 to disconnect and pop out of the battery pack 102.
Figure 4 illustrates a battery pack layout with a grid setup in accordance with an embodiment of the present disclosure. Referring to Figure 4, the overall structure of the battery pack 102 features the cylindrical battery cells 104 arranged in a grid formation. Each of the cylindrical battery cell 104 represents an individual battery cell 104, commonly used in high-density battery packs for applications like electric vehicles. Above the battery cell 104, a grid of the heat sensitive strips 106 forms a criss-cross pattern across the plurality of battery cell 104. The heat-sensitive strips 106 are configured to detect overheating of the battery cell 104 by expanding when exposed to elevated temperatures, particularly when the temperature exceeds a threshold, such as 75°C. The heat-sensitive strips 106 serve as a passive detection system, which operates without the need for continuous external power, making it energy-efficient and highly reliable.
At the end of the heat sensitive strips 106 or designated points along the heat sensitive strips 106, the button switches 108 are strategically placed. The button switches 108 are triggered when the heat sensitive strips 106 expand due to heat, allowing the system to accurately pinpoint the specific battery cell 104 that is experiencing thermal runaway or excessive heating. Once activated, the button switch 108 disconnects the electric connection and the microprocessor 112 is connected to the button switch 108 to receive the electric signal from the heat sensitive strips 106. The microprocessor 112 processes the information and communicates the status to the vehicle's control system.
Figure 5 illustrates a top view of cell connection in accordance with an embodiment of the present disclosure. Figure 5 provides a detailed view of the electrical connections on top of the cylindrical battery cells 104. At the top of the battery cell 104 features metallic strips that act as electrical conductors for the battery cell 104, forming the primary connection interface for power distribution within the battery pack 102. The connections are integrated with the breakable links 118 intentionally weakened points configured to sever under specific conditions, such as excessive heat caused by thermal runaway in a particular cell. When a cell overheats, the breakable links 118 at the top of the battery cell 104 ensure that the affected cell is safely disconnected from the electrical circuit.
The breakable links 118 are crucial for preventing the faulty cell from causing damage to the entire battery pack 102, as they allow the overheated battery cell 104 to be isolated without disrupting the functionality of the other cells. In conjunction with the thermally sensitive membrane, that supports the ejection mechanism, the configuration ensures that once the cell reaches a critical temperature, it is ejected from its slot, severing the electrical connections safely. The rest of the battery pack 102 remains operational due to the modular configuration of the cell-to-cell connection links, ensuring continued performance even after the removal of one or more compromised cells.
Figure 6 illustrates a structural layout of the top plate 102a layout and the bottom plate 102b layout of the battery pack 102 in accordance with an embodiment of the present disclosure. The top plate 102a consists of the grid-like arrangement of the heat sensitive strips 106, and the plurality of button switches 108 , the heat sensitive strips 106 are configured to expand when exposed to heat above the threshold temperature, and expansion of the heat sensitive strips 106 push or trigger the button switches 108 to receive the electrical signal from the heat sensitive strips 106 and sends the electrical signal to the microprocessor 112 when a cell begins to overheat.
The bottom plate 102b layout consists of circular cutouts or slots that hold the battery cell 104 and consist of the thermally sensitive membrane 110, and the bottom plate 102 layout is engineered to accommodate a mechanical ejection mechanism. When the battery cell 104 overheats, the membrane beneath the battery cell 104 melts, triggering the ejection process, the ejection mechanism, allowing the faulty cell to be removed from the battery pack 102, ensures that the battery pack 102 continues to operate safely, even when individual cells are compromised.
Figure 7 illustrates a top and bottom plate with the embedded ceramic heat sensitive strips 106 and breakable cell connections in accordance with an embodiment of the present disclosure. Figure 7 consists of the top plate 102a and the bottom plate 102b of the battery pack 102. The top plate 102a consists of the grid of the ceramic heat sensitive strips 106 embedded into it, arranged in a pattern to cover the battery cell 104 beneath. The ceramic heat sensitive strips 106 are made from heat-sensitive materials such as zirconia, which expand when exposed to heat, purpose is to detect thermal runaway conditions by expanding when a specific cell overheats, triggering the small button switches 108 located at the end of the strips.
The bottom plate 102b consists of the breakable electrical connections for each cell are integrated. The connections feature weak links, configured to be slightly cracked but still able to conduct electricity. Under normal conditions, the electrical flow continues uninterrupted. The temperature of the battery cell 104 rises significantly, and the thermally sensitive membrane 110 placed under that cell melts, allowing the weight of the cell to break the weakened connection. The disconnection isolates the faulty cell from the rest of the battery pack 102, stopping the flow of electricity to the faulty cell and ejecting it from the system 100. Together, the top plate 102a detects overheating, while the bottom plate 102b facilitates the ejection of the overheating battery cell 104. This modular configuration allows for easy cell removal and replacement, minimizing the risk of damage to the rest of the battery pack 102 and maintaining the battery's overall functionality during a thermal runaway event.
Figure 8 illustrates a detailed view of the ceramic heat sensitive strips 106 layouts, the button switches 108, and the thermally sensitive membrane 110 with the breakable links 118 in accordance with an embodiment of the present disclosure. Figure 8 represents the front view of the battery pack 102 with the top plate 102a and the bottom plate 102b, the top plate 102a consists of the heat sensitive strips 106 and the button switches 108 and the bottom plate 102b consists of the thermally sensitive membrane 110 with the breakable links 118. The ceramic heat sensitive strips 106 form a grid-like structure that spans the battery cell 104, with the small button switches 108 located where the end of the heat-sensitive strip 106. The ceramic heat sensitive strips 106 are composed of heat-sensitive material that expands when exposed to high temperatures (typically above 75°C), which occurs when a cell begins to experience thermal runaway. The expansion of the ceramic heat sensitive strips 106 activates the button switches 108, sending an electrical signal to the microprocessor 112, allowing the system 100 to accurately identify the overheating cell, without the need for power-hungry sensors or complex electronics, thus maintaining energy efficiency.
The bottom plate 102b of the battery pack 102 consists of the thermally sensitive membrane 110 and the breakable links 118 embedded in the system. The thermally sensitive membrane 110, made from materials like paraffin wax, is placed under each cell. When a cell overheats, the thermally sensitive membrane 110 melts, causing the cell's weight to break the breakable link 118. The breakable links 118 are intentionally configured with slight cracks so that, once a critical temperature is reached, they sever the connection and physically eject the overheating cell from the battery pack 102. The disconnection not only isolates the failing cell but also prevents it from causing a chain reaction or further damage to other cells.
Figure 9 illustrates a side view of the battery pack 102 compartments with ejection and detection systems in accordance with an embodiment of the present disclosure. Figure 9 provides a comprehensive side view of the battery pack 102 compartment, illustrating both the heat detection and cell ejection mechanism in action. The top plate 102a of the battery pack 102, the grid of the ceramic heat sensitive strips 106 is placed beneath the top plate 102a. The heat sensitive strips 106 serve as the primary heat detection mechanism. As the battery cell 104 cell begins to overheat, the heat sensitive strips 106 in that cell's row and column expand, triggering the button switches 108 that identify the specific overheating cell. The bottom plate 102b represents the ejection mechanism. Each cell of the plurality battery cells 104 rests on the thermally sensitive membrane 110, made from materials like paraffin wax. When a cell's temperature exceeds 75°C, the thermally sensitive membrane 110 beneath the cell melts, causing the cell's electrical connection to break and allowing it to "pop out" from the battery pack 102.
The mechanism is entirely mechanical and energy-efficient, requiring no additional sensors or power-consuming components. The ejected cell is physically separated from the rest of the battery pack 102, preventing further damage or the spread of thermal runaway to adjacent cells. The dual system of detection and ejection ensures that the battery pack remains operational even after a cell has been ejected, maintaining the vehicle's functionality and improving safety by minimizing the risks associated with battery overheating.
In an operative configuration, the system 100 for detecting and ejecting an overheated battery cell 104 of an electric vehicle is configured to eliminate the risk of explosion due to thermal runaway. The system 100 begins with the battery pack 102, which includes the top plate 102a and the bottom plate 102b. The top plate 102a of the battery pack 102 includes the heat sensitive strips 106 embedded into it, arranged in a pattern to cover the plurality of battery cell 104 beneath, and the plurality of button switches 108 is located at the end of the heat-sensitive strips 106. The bottom plate 102b is configured with the breakable links 118 and each link is slightly cracked and configured to fully break when the overheated battery cell 104 is ejected, thereby disconnection the overheated battery cell 104 from the electric circuit.
Further, the plurality of battery cells 104 integrated inside the battery pack 102 in an electric circuit connection, each of the battery cell 104 is arranged in a matrix formation and the heat sensitive strip 106 is placed across the plurality of battery cells 104 configuring a criss-cross pattern across the plurality of battery cells 104. The heat sensitive strips 106 are configured to expand when exposed to heat above a threshold temperature.
Further, the plurality of button switches 108 is formed at the end of the heat sensitive strips 106, the button switch 108 activates when the heat sensitive strips 106 expand due to the heat of the battery cell 104. The heat-sensitive strips 106 are arranged in a matrix formation, when the specific battery cell 104 gets heated it expands the heat sensitive strip 106 over the specific battery cell 104 and after expansion, the specific heat sensitive strips 106 trigger an electric signal and further triggers the particular button switch 108 and send an electric signal to the microprocessor 112, enables the system 100 to accurately identify which specific cell is overheated.
The microprocessor 112 is connected to the plurality of button switches 108 to receive the electric signal from the heat sensitive strips 106 and process the electric signal to identify the overheated battery cell 104 from the battery pack 102. The communication interface 114 is configured to cooperate with the microprocessor 112 to transmit the location of the overheated battery cell 104 on the display module 116 or management information display (MID), providing real-time information about the affected cell and alerting the user to the presence of an overheating condition. Additionally, in cases where the temperature rise indicates an imminent thermal runaway, the microprocessor may trigger the ejection mechanism by initiating the melting of the membrane beneath the affected cell.
To eject the overheated battery cell 104 from the battery pack 102, the system 100 incorporates the thermally sensitive membrane 110 connected to the bottom plate 102b of the battery pack 102 and placed underneath each of the plurality of battery cell 104 and melts when exposed to the heat beyond the threshold temperature. The thermally sensitive member 110 allows the automatic ejection of the overheating battery cell 104 from the battery pack 102 and effectively isolates the damaged battery cell 104 from the battery pack 102.
Advantageously, the system 100 for detecting and ejecting an overheated battery cell 104 of an electric vehicle represents a significant advancement in battery safety management through thermal detection and ejection mechanisms. The system 100 eliminates the need for continuous external power by utilizing the heat-sensitive strips 106 that expand in response to elevated temperatures, providing a passive and energy-efficient monitoring solution. This passive operation reduces power consumption and increases the system's reliability, as it functions autonomously without relying on complex electronic sensors or cooling mechanisms. Upon detecting thermal runaway, the system 100 can accurately isolate and eject the overheated battery cell 104, preventing the spread of heat and mitigating damage to adjacent cells. The integration of the breakable links 118 within the top and bottom plates ensures that the cell's electrical connections are severed, maintaining the safety and operational continuity of the remaining battery cells 104. The thermally sensitive membrane 110 ensures that the faulty cell is physically removed from the battery pack 102, further preventing the escalation of thermal events. The microprocessor 112 processes the electric signal and transmits real-time alerts to the vehicle's dashboard, allowing the driver to take immediate action. These advancements collectively enhance the system's safety, durability, and efficiency by combining mechanical fail-safes with electronic controls. As a result, the system 100 offers a cutting-edge, proactive solution to battery thermal management, significantly improving the safety and longevity of the battery pack 102 of electric vehicles.
The functions described herein may be implemented in hardware, software executed by a processor, firmware, or any combination thereof. If implemented in software executed by a processor, the functions may be stored on or transmitted over as one or more instructions or codes on a computer-readable medium. Other examples and implementations are within the scope and spirit of the disclosure and appended claims. For example, due to the nature of software, functions described above can be implemented using software executed by a processor, hardware, firmware, hardwiring, or combinations of any of these. Features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations.
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a system and a method for detecting and ejecting an overheated battery cell 104 of an electric vehicle that:
• enables easy ejection and disconnection of individual cells to enhance safety;
• identifies the exact overheating cell using a passive, mechanical method without the need for complex electronic sensors;
• monitors cell temperature without the need for constant power;
• isolates the damaged cell from the battery to prevent further damage;
• reduces operational costs by eliminating the need for complex electronic sensors and cooling mechanisms;
• ensures safety is maintained without compromising the functionality of another component;
• reduces the need for costly battery replacement and improves the efficiency of energy storage systems;
• promotes suitable use of energy storage technology; and
• provides scalability to adapt different battery sizes and configurations.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression "at least" or "at least one" suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A system (100) for detecting and ejecting an overheated battery cell (104) of an electric vehicle, said system (100) comprises:
• a battery pack (102) includes a top plate (102a) and a bottom plate (102b);
• a plurality of battery cells (104) integrated inside said battery pack (102) in an electric circuit connection to power the electric vehicle;
• heat-sensitive strips (106) placed across said plurality of battery cells (104) and electrically connected to said top plate (102a) of the battery pack (102), each of said heat-sensitive strips (106) configured to detect overheating of a battery cell (104) by expanding when exposed to heat above a threshold temperature, said expansion triggering an electrical signal;
• a plurality of button switches (108) formed at the end of said heat-sensitive strip (106) and each of the button switches (108) is configured to be triggered upon expansion of the heat-sensitive strip (106) and disconnect an electrical connection with the overheated battery cell (104);
• a thermally-sensitive membrane (110) connected to said bottom plate (102b) and placed underneath each of said plurality of battery cells (104) and configured to melt when exposed to heat beyond the threshold temperature, causing the overheated battery cell (104) to be mechanically ejected from said battery pack (102); and
• a microprocessor (112) communicatively connected to said plurality of button switches (108) to:
o receive said electrical signal from the heat-sensitive strips (106); and
o process the electrical signal to identify the overheated battery cell (104) from said battery pack (102).
• a communication interface (114) communicatively connected to said microprocessor (112) to:
o transmit the location of the overheated battery cell (104) on a display module (116) of the electric vehicle for real-time alerts.
2. The system (100) as claimed in claim 1, wherein said threshold temperature is 75°C.
3. The system (100) as claimed in claim 1, wherein said microprocessor (112) is further configured to continuously monitor the electrical signals from the said heat sensitive strips (106).
4. The system (100) as claimed in claim 1, wherein said thermally-sensitive membrane (110) is a paraffin wax configured to melt at the threshold temperature to facilitate the ejection of the overheated battery cell (104).
5. The system (100) as claimed in claim 1, wherein said heat-sensitive strips (106) are ceramic strips placed in a matrix pattern across the plurality of battery cells (104) and configured to expand when exposed to heat so as to trigger the button switches (108) by expansion.
6. The system (100) as claimed in claim 1, wherein said heat sensitive strips (106) are composed of zirconia.
7. The system (100) as claimed in claim 1, wherein said bottom plate (102b) is configured with breakable links 118, and each link is slightly cracked and configured to fully break when the overheated battery cell (104) is ejected, thereby disconnecting the overheated battery cell (104) from the electric circuit.
8. The system (100) as claimed in claim 1, wherein said display module (116) is a vehicle's dashboard of the electric vehicle to receive the alert from the microprocessor (112).
9. The system (100) as claimed in claim 8, wherein the vehicle's dashboard includes a visual and audio alert mechanism triggered by the microprocessor (112) to notify a driver in real-time of the exact location and status of the overheated battery cell (104).
10. The system (100) as claimed in claim 1, wherein the microprocessor (112) is further configured to record multiple overheating events, allowing the ejection of more than one overheated battery cell (104) in the event of simultaneous thermal runaway occurrences.
11. The system (100) as claimed in claim 1, wherein the system (100) operates in a passive state, requiring no continuous external power supply for the heat-sensitive strips (106).
12. A method for detecting and ejecting an overheated battery cell (104) in an electric vehicle, comprising the steps of:
• monitoring by heat sensitive strips (106), overheating of each of a plurality of battery cells (104) of a battery pack (102);
• detecting, by the heat sensitive strips (106), a overheated battery cell (104) by expanding when exposed to heat above a threshold temperature;
• triggering, by the heat sensitive strips (106), an electrical signal upon expansion of a heat sensitive strip (106) in response to overheating;
• disconnecting, by a button switch (108), an electrical connection of the overheated battery cell (104) upon being triggered by the expansion of the heat sensitive strip (106);
• melting a thermally-sensitive membrane (110) placed underneath the overheated battery cell (104), when exposed to heat beyond the threshold temperature, thereby causing the overheated battery cell (104) to be mechanically ejected from the battery pack (102);
• receiving the electrical signal from the heat-sensitive strip (106) by a microprocessor (112);
• processing the electrical signal by the microprocessor (112) to identify a location of the overheated battery cell (104) of the battery pack (102); and
• transmitting, by a communication interface (114), the location of the overheated battery cell (104) to a display module (116) for real-time alerts.

Dated this 08th Day of November, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA - 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT CHENNAI

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