Battery thermal event detection system using a thermally interruptible electrical conductor

• US 8,059,007 B2
• Filed: 05/28/2009
• Issued: 11/15/2011
• Est. Priority Date: 05/28/2009
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Brncic, Daniel Nicholas, Hall, Jonathan Louis, Kohn, Scott Ira, Kreiner, Paul Bryan, Hermann, Weston Arthur, West, Dorian
• Primary Examiner(s): Nguyen; Tai T
• Application Number:
  US12/455,198
• Publication Number:
  US 20100302051A1
• Time in Patent Office: 901 Days
• Field of Search: 340/636.11, 340/636.12, 340/636.14, 340/641, 340/643, 340/691.6, 320/106, 320/134, 320/150, 320/153, 320/154, 324/427, 324/430, 324/431
• US Class Current: 340/636.11
• CPC Class Codes: H01M 10/486 for measuring temperature
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A method and apparatus is provided for determining when a battery, or one or more batteries within a battery pack, undergoes an undesired thermal event such as thermal runaway. The system uses a conductive member mounted in close proximity to, or in contact with, an external surface of the battery or batteries to be monitored. A resistance measuring system such as a continuity-tester or an ohmmeter is coupled to the conductive member, the resistance measuring system outputting a first signal when the temperature corresponding to the battery or batteries is within a prescribed temperature range and a second signal when the temperature exceeds a predetermined temperature that falls outside of the prescribed temperature range.

Claims

1. A detection system for detecting a battery thermal event, the detection system comprising:

at least one battery;

a conductive member comprised of a first end portion, a second end portion, and a region there between, wherein a portion of said region is proximate to an external surface of said at least one battery;

a resistance measuring system coupled to said first and second end portions of said conductive member, wherein said resistance measuring system outputs a first signal when said at least one battery is operating within a prescribed temperature range and outputs a second signal when a temperature corresponding to said at least one battery exceeds a predetermined temperature, wherein said predetermined temperature is outside of said prescribed temperature range; and

a system controller coupled to said resistance measuring system, wherein said system controller performs a predetermined response when said system controller receives said second signal from said resistance measuring system, said predetermined response selected from the group of responses consisting of (i) activating a warning indicator, (ii) activating a battery cooling system, (iii) activating a fire control system, and/or (iv) transmitting a thermal event notification report via a communication system coupled to said system controller.

2. The detection system of claim 1, wherein said at least one battery corresponds to one battery of a plurality of batteries, wherein said region of said conductive member is proximate to each of said plurality of batteries, and wherein said resistance measuring system outputs said second signal when a battery temperature corresponding to any of said plurality of batteries exceeds said predetermined temperature.

3. The detection system of claim 1, wherein said conductive member is elongated and cylindrically shaped.

4. The detection system of claim 1, wherein said resistance measuring system is comprised of a continuity-tester.

5. The detection system of claim 1, wherein said conductive member is severed when said temperature corresponding to said at least one battery exceeds said predetermined temperature.

6. The detection system of claim 1, wherein said resistance measuring system is comprised of an ohmmeter.

7. The detection system of claim 1, wherein a resistance corresponding to said conductive member and monitored by said resistance measuring system is within a first range of resistivities when said at least one battery is operating within said prescribed temperature range and within a second range of resistivities when said temperature corresponding to said at least one battery exceeds said predetermined temperature.

8. The detection system of claim 1, wherein said conductive member is comprised of a metal.

9. The detection system of claim 1, wherein said conductive member is comprised of a non-metallic material that contains a conductive material.

10. The detection system of claim 9, wherein said non-metallic material is comprised of a plastic.

11. The detection system of claim 9, wherein said metallic material is selected from the group consisting of carbon powders, carbon fibers and metallic powder.

12. The detection system of claim 1, wherein said conductive member is in contact with said external surface of said at least one battery.

13. The detection system of claim 1, further comprising a bonding material, said bonding material holding said conductive member in place relative to said at least one battery.

14. The detection system of claim 1, further comprising a mechanical clip, said mechanical clip holding said conductive member in place relative to said at least one battery.

15. The detection system of claim 1, wherein said conductive member is coated with an electrically non-conducting material.

16. The detection system of claim 1, further comprising an electrically non-conducting tube, wherein said region of said conductive member is contained within said electrically non-conducting tube.

17. The detection system of claim 1, further comprising a second conductive member, wherein said resistance measuring system is intermittently coupled to said second conductive member to validate resistance measuring system operation.

18. The detection system of claim 1, further comprising a calibration member, wherein said resistance measuring system is intermittently coupled to said calibration member to calibrate operation of said resistance measuring system.

19. A detection system for detecting a battery thermal event, the detection system comprising:

a plurality of batteries;

a first conductive member proximate to each battery of a first subset of said plurality of batteries;

a second conductive member proximate to each battery of a second subset of said plurality of batteries;

a first resistance measuring system coupled to said first conductive member, wherein said first resistance measuring system outputs a first thermal event notification signal when a first temperature associated with at least one battery of said first subset of said plurality of batteries exceeds a predetermined temperature;

a second resistance measuring system coupled to said second conductive member, wherein said second resistance measuring system outputs a second thermal event notification signal when a second temperature associated with at least one battery of said second subset of said plurality of batteries exceeds said predetermined temperature; and

a system controller coupled to said first and second resistance measuring systems, wherein said system controller performs a predetermined response when said system controller receives either said first thermal event notification signal from said first resistance measuring system or said second thermal event notification signal from said second resistance measuring system, said predetermined response selected from the group of responses consisting of (i) activating a warning indicator, (ii) activating a battery cooling system, (iii) activating a fire control system, and/or (iv) transmitting a thermal event notification report via a communication system coupled to said system controller.

20. The detection system of claim 19, wherein a multiplexed resistance measuring system comprises said first and second resistance measuring systems.

21. A method for detecting a battery thermal event, the method comprising steps of:

positioning a conductive member in proximity to an external surface of at least one battery;

determining continuity of said conductive member, wherein continuity is severed when a battery temperature corresponding to said at least one battery exceeds a predetermined temperature;

outputting a first signal to a system controller when said conductive member exhibits continuity during said determining step;

outputting a second signal to said system controller when continuity of said conductive member is severed indicating said battery temperature corresponding to said at least one battery has exceeded said predetermined temperature and

performing a predetermined response when said system controller receives said second signal, said predetermined response selected from the group of responses consisting of (i) activating a warning indicator, (ii) activating a battery cooling system, (iii) activating a fire control system, and/or (iv) transmitting a thermal event notification report via a communication system coupled to said system controller.

22. A method for detecting a battery thermal event, the method comprising steps of:

positioning a conductive member in proximity to an external surface of at least one battery;

measuring a resistance corresponding to said conductive member, wherein said resistance is within a first range of resistivities when a battery temperature corresponding to said at least one battery is within a prescribed temperature range, and wherein said resistance is within a second range of resistivities when said battery temperature exceeds a predetermined temperature, wherein said predetermined temperature is outside of said prescribed temperature range;

outputting a first signal to a system controller when said resistance is within said first range of resistivities;

outputting a second signal to said system controller when said resistance is within said second range of resistivities and

performing a predetermined response when said system controller receives said second signal, said predetermined response selected from the group of responses consisting of (i) activating a warning indicator, (ii) activating a battery cooling system, (iii) activating a fire control system, and/or (iv) transmitting a thermal event notification report via a communication system coupled to said system controller.