1. A system (200) for early detection, prediction and suppression of thermal runaway in a battery (100), the system (200) comprising: sensing unit (202) disposed at a cell level and a module level within the battery (100), the sensing unit (202) being adapted to detect battery operating parameters comprising temperature, pressure, electrical characteristics, and gas emissions indicative of abnormal battery behavior; an input interface (204) operatively coupled to the sensing unit (202) and adapted to receive detected battery operating parameters; an input conditioning unit (206) adapted to preprocess the received battery operating parameters by performing noise filtering, normalization, and anomaly conditioning to generate conditioned parameter data; and a processing unit (208) operatively coupled to the input conditioning unit (206) and a memory (210) storing executable instructions, characterized in that the processing unit (208) is configured to: receive the detected battery operating parameters from the input conditioning unit (206); analyse the conditioned parameter data using predictive models; determine a likelihood of thermal runaway prior to ignition of cells (102a-102n) of the battery (100); and generate control decisions based on the determined likelihood.

2. The system (200) as claimed in claim 1, comprising an output conditioning unit (212) configured to format the generated control decisions into actuation control signals.

3. The system (200) as claimed in claim 1, comprising an output interface (214) configured to transmit the actuation control signals.

4. The system (200) as claimed in claim 1, comprising fire-suppressant micro-capsules (216), disposed within or between the cells (102a-102n) of the battery (100) and operatively coupled to the output interface (214), adapted to rupture in response to the actuation control signals or upon reaching a predefined thermal threshold, to release a fire-suppressant agent to suppress thermal runaway at a cell level.

5. The system (200) as claimed in claim 1, comprising a containment unit (218) adapted to isolate the cells (102a-102n) of the battery (100) after release of the fire-suppressant agent to prevent propagation of heat and flame to adjacent cells (102a-102n) of the battery (100).

6. The system (200) as claimed in claim 1, wherein the sensing unit (202) comprises a temperature sensor, a pressure sensor, a voltage sensor, a current sensor, a gas detection sensor, or a combination thereof.

7. The system (200) as claimed in claim 1, wherein the processing unit (208) is configured to select or adapt a predictive model based on battery usage patterns, charging conditions, or environmental operating conditions.

8. The system (200) as claimed in claim 1, wherein the processing unit (208) is configured to continuously update the likelihood of thermal runaway at predefined time intervals during battery operation.

9. The system (200) as claimed in claim 1, comprising an alert unit (220) configured to generate a local or remote alert when the determined likelihood of thermal runaway exceeds a predefined threshold.

10. A method (400) for early detection, prediction, and suppression of thermal runaway in the battery (100), the method (400) is characterized by steps of: detecting battery operating parameters, using sensing unit (202) disposed at a cell level and a module level within the battery (100); receiving the detected battery operating parameters through an input interface (204); pre-processing the received battery operating parameters using an input conditioning unit (206) to perform noise filtering, normalization, and anomaly conditioning to generate conditioned parameter data; processing, using a processing unit (208) coupled to a memory (210) storing executable instructions, the conditioned parameter data to analyse abnormal battery behaviour; predicting, using the processing unit (208), a likelihood of thermal runaway prior to ignition of cells (102a-102n) of the battery (100); generating actuation control signals based on the predicted likelihood of thermal runaway; releasing a fire-suppressant agent from fire-suppressant micro-capsules (216) disposed within or between the cells (102a-102n) of the battery in response to the actuation control signals or upon reaching a predefined thermal threshold; isolating affected cells (102a–102n) using a containment unit (218) to prevent propagation of heat and flame to adjacent cells; reducing thermal energy of the battery (100) using a cooling unit (220) configured to absorb heat and limit propagation of thermal runaway; and venting gases released from the battery (100) using a venting unit (222) to reduce internal pressure and prevent structural damage or explosion of the battery (100). Date: February 25, 2026 Place: Noida Nainsi Rastogi Patent Agent (IN/PA-2372) Agent for the Applicant

Description:BACKGROUND
Field of Invention
[001] Embodiments of the present invention generally relate to battery safety and protection and particularly to a system and method for detection, prediction and suppression of fire in a battery.
Description of Related Art
[002] Lithium-ion battery systems face a critical safety challenge due to thermal runaway events that arise from overcharging, internal short circuits, mechanical damage, manufacturing defects, or external heat exposure. A single cell failure often leads to rapid temperature rise, release of flammable gases, fire, or explosion.
[003] Such events pose severe risks to human safety, property, and infrastructure, particularly in electric vehicles, energy storage installations, aerospace systems, and portable electronic devices. The high energy density of lithium-ion batteries further amplifies the severity of these incidents and demands robust safety mechanisms.
[004] Existing approaches rely primarily on battery management systems that track voltage, current, and temperature parameters to detect abnormal operating conditions. Additional measures include passive thermal barriers, cooling plates, venting paths for gas release, and external firefighting systems such as water, foam, or gaseous agents.
[005] Certain designs further employ fire-retardant materials, ceramic separators, or structural reinforcement within battery enclosures to delay heat transfer between cells. These techniques aim to reduce damage severity and improve response after fault detection.
[006] However, current solutions remain largely reactive in nature and respond only after abnormal conditions reach predefined thresholds. Battery management systems lack direct capability to suppress fire at the cell level, while passive barriers merely delay heat propagation without extinguishing the source.
[007] External firefighting methods prove ineffective within sealed battery packs and introduce electrical or chemical hazards. Furthermore, reliance on limited sensing parameters results in delayed detection and inadequate prevention of cascading cell failure. These limitations leave a significant gap in effective, proactive battery fire safety.
[008] There is thus a need for an improved and advanced system and method for detection, prediction and suppression of fire in a battery that can administer the aforementioned limitations in a more efficient manner.
SUMMARY
[009] Embodiments in accordance with the present invention provide a system for detection, prediction and suppression of fire in a battery. The system comprising sensing unit disposed at a cell level and a module level within the battery. The sensing unit being adapted to detect battery operating parameters selected from a temperature, a pressure, an electrical characteristics, a gas emissions, or a combination thereof indicative of abnormal battery behavior. The system further comprising an input interface operatively coupled to the sensing unit and adapted to receive detected battery operating parameters. The system further comprising an input conditioning unit adapted to preprocess the received battery operating parameters by performing noise filtering, normalization, and anomaly conditioning to generate conditioned parameter data. The system further comprising a processing unit operatively coupled to the input conditioning unit and a memory storing executable instructions. The processing unit configured to receive the detected battery operating parameters from the input conditioning unit; analyze the conditioned battery operating parameters data using predictive models; determine a likelihood of thermal runaway prior to ignition of a cell of the battery; and generate control decisions based on the determined likelihood; an output conditioning unit configured to format the generated control decisions into actuation control signals; an output interface configured to transmit the actuation control signals. The system further comprising: fire-suppressant micro-capsules disposed within or between cells of the battery and operatively coupled to the output interface, the fire-suppressant micro-capsules being configured to rupture in response to the actuation control signals or upon reaching a predefined thermal threshold, thereby releasing a fire-suppressant agent to suppress thermal runaway at the cell level.
[0010] Embodiments in accordance with the present invention further provide a method for detection, prediction and suppression of fire in a battery. The method comprising steps of detecting battery operating parameters, using sensing unit disposed at a cell level and a module level within the battery; receiving the detected battery operating parameters through an input interface; pre-processing the received battery operating parameters using an input conditioning unit to perform noise filtering, normalization, and anomaly conditioning to generate conditioned parameter data; processing, using a processing unit coupled to a memory storing executable instructions, the conditioned parameter data to analyse abnormal battery behavior; predicting, using the processing unit, a likelihood of thermal runaway prior to ignition of cells of the battery; generating actuation control signals based on the predicted likelihood of thermal runaway; releasing a fire-suppressant agent from fire-suppressant micro-capsules disposed within or between the cells of the battery in response to the actuation control signals or upon reaching a predefined thermal threshold; isolating affected cells using a containment unit to prevent propagation of heat and flame to adjacent cells; reducing thermal energy of the battery using a cooling unit configured to absorb heat and limit propagation of thermal runaway; and venting gases released from the battery using a venting unit to reduce internal pressure and prevent structural damage or explosion of the battery.
[0011] Embodiments of the present invention may provide a number of advantages depending on their particular configuration. First, embodiments of the present application may provide a system for detection, prediction and suppression of fire in a battery.
[0012] Next, embodiments of the present application may provide a system that provides early and proactive mitigation of thermal runaway by predicting abnormal battery conditions prior to ignition, thereby enhancing overall operational safety of the battery.
[0013] Next, embodiments of the present application may provide a system that enables localized fire suppression at a cell level, that reduces the risk of fire propagation to adjacent cells and minimizes damage to the battery pack and surrounding components.
[0014] Next, embodiments of the present application may provide a system that integrates detection, prediction, suppression, and containment within a single framework, that improves system reliability and reduces dependence on external firefighting mechanisms.
[0015] Next, embodiments of the present application may provide a system that improves response accuracy through multi-parameter sensing and intelligent analysis, that lowers false alarms and ensures timely activation of protective measures.
[0016] Next, embodiments of the present application may provide a system that supports scalable and modular deployment across diverse applications, including electric vehicles, energy storage systems, aerospace platforms, and consumer electronics, without substantial redesign of battery architecture.
[0017] These and other advantages will be apparent from the present application of the embodiments described herein.
[0018] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The above and still further features and advantages of embodiments of the present invention will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, and wherein:
[0020] FIG. 1 illustrates a schematic diagram of a battery, according to an embodiment of the present invention;
[0021] FIG. 2 illustrates a block diagram of a system for detection, prediction and suppression of fire in the battery, according to an embodiment of the present invention;
[0022] FIG. 3 illustrates a block diagram of a processing unit of the system, according to an embodiment of the present invention; and
[0023] FIG. 4 depicts a flowchart of a method for detection, prediction and suppression of fire in the battery, according to an embodiment of the present invention.
[0024] The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures. Optional portions of the figures may be illustrated using dashed or dotted lines, unless the context of usage indicates otherwise.
DETAILED DESCRIPTION
[0025] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the scope of the invention as defined in the claims.
[0026] In any embodiment described herein, the open-ended terms "comprising", "comprises”, and the like (which are synonymous with "including", "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of", “consists essentially of", and the like or the respective closed phrases "consisting of", "consists of”, the like.
[0027] As used herein, the singular forms “a”, “an”, and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.
[0028] FIG. 1 illustrates a battery 100, in an embodiment of the present invention. In an embodiment of the present invention, the battery 100 may serve as an electrical energy storage unit for various applications such as electric mobility systems, stationary energy storage installations, aerospace platforms, and electronic devices. In general, the battery 100 may comprise electrochemical cells arranged in a defined electrical configuration to provide a required voltage, current, and capacity. The battery 100 may include structural components that provide mechanical support, electrical insulation, and protection from environmental factors. Such batteries may include provisions for electrical interconnections, thermal spacing, and gas venting to support safe operation under normal and abnormal conditions.
[0029] In an embodiment of the present invention, the battery 100 may comprise cells 102a-102n (hereinafter referred individually to as the cell 102, and plurally to as the cells 102). In another embodiment of the present invention, the battery 100 may further comprise a lithium-ion battery pack formed by a plurality of lithium-ion cells arranged in series, parallel, or series-parallel combinations. The lithium-ion cells may include cylindrical cells, prismatic cells, pouch cells, or combinations thereof. The cells are assembled into battery modules that maintain cell alignment, electrical continuity, and thermal separation. The battery modules may enclose within the battery housing that may provide structural rigidity and protection against mechanical and thermal stress. Each lithium-ion cell includes an anode, a cathode, an electrolyte, and a separator configured to support reversible electrochemical reactions during charge and discharge cycles. Electrical terminals of the cells connect through conductive interconnects or busbars to form the electrical architecture of the battery 100. The arrangement of cells and modules may support uniform current distribution and stable electrical performance during operation. Embodiments of the present invention are intended to include or otherwise cover any type of battery 100, including known lithium-ion cell chemistries, related art configurations, and/or later developed cell 102 of the battery 100 technologies that provide electrical energy storage within the battery 100.
[0030] The battery 100 may further include thermal and safety features disposed between or around the cells 102. Such features may include insulating layers, spacing elements, or cooling interfaces that assist in temperature regulation. The battery housing may define venting passages that guide gases released from the cells 102 of the battery 100 toward designated outlets. The structural configuration of the battery 100 may allow integration of monitoring, suppression, and containment components described with reference to subsequent figures.
[0031] In another embodiment of the present invention, the battery 100 may comprise a set of batteries arranged as multiple battery packs or battery units electrically coupled in series, parallel, or series-parallel configurations. The set of batteries may operate as a combined energy storage system that supplies power to a common load or to multiple loads. Each battery 100 within the set may independently experience variations in temperature, pressure, electrical characteristics, or gas release. In an embodiment of the present invention, a system 200 (as shown in FIG. 2) described herein may be implemented for each individual battery within the set, thereby enabling monitoring, prediction, suppression, and containment functions at a battery-level or sub-battery-level granularity. This configuration supports deployment in large-scale energy storage installations, modular electric vehicle platforms, and distributed power systems where multiple batteries operate together.
[0032] FIG. 2 illustrates a block diagram of a system 200 for detection, prediction and suppression of fire in the battery 100, according to an embodiment of the present invention. In an embodiment of the present invention, the system 200 may be configured to provide real-time monitoring of battery operating conditions, predictive analysis of abnormal behavior, and localized suppression of incipient fire events. The system 200 may support safe and reliable operation of high-energy battery systems by reducing the risk of uncontrolled fire propagation within the battery 100.
[0033] In an embodiment of the present invention, the system 200 may be implemented for each battery 100 within a set of batteries arranged as multiple battery packs or battery units. Each battery 100 within the set may independently interact with the system 200, thereby enabling distributed monitoring, prediction, suppression, and containment across large-scale or modular energy storage configurations.
[0034] In an embodiment of the present invention, the system 200 may operate in a continuous or event-driven manner to monitor battery conditions during charging, discharging, or idle states. The system 200 may support deployment across a range of battery-powered applications while maintaining robustness, adaptability, and consistent safety response under varying operating conditions.
[0035] In an embodiment of the present invention, the system 200 may operate as an integrated multi-layer safety architecture configured to detect abnormal operating conditions, predict likelihood of thermal runaway, suppress combustion at a cell level, isolate affected cells, reduce thermal energy, and safely vent gases. The integrated operation of detection, prediction, suppression, containment, cooling, and venting mechanisms may provide comprehensive protection of the battery 100.
[0036] According to the embodiments of the present invention, the system 200 may incorporate non-limiting hardware components to enhance the processing speed and efficiency such as the system 200 may comprise an sensing unit 202, an input interface 204, an input conditioning unit 206, a processing unit 208, a memory 210, an output conditioning unit 212, and an output interface 214, a fire-suppressant micro-capsules 216, a containment unit 218, a cooling unit 220, a venting unit 222, an alert unit 224, and a power supply unit 226. In an embodiment of the present invention, the hardware components of the system 200 may be integrated with computer-executable instructions for overcoming the challenges and the limitations of the existing systems.
[0037] In an embodiment of the present invention, the sensing unit 202 may be disposed at a cell level, module level, or battery level and may be adapted to detect operating parameters of the battery 100. The operating parameters may be indicative of a health and safety conditions of the battery 100. The detected operating parameters may comprise, but not limited to, temperature, pressure, voltage, current, and gas presence associated with electrochemical activity within cells 102 of the battery 100, and so forth. Embodiments of the present invention ()are intended to include or otherwise cover any type of the operating parameters, including known, related art, and/or later developed sensing technologies.
[0038] In an embodiment of the present invention, temperature signals captured by the sensing unit 202 may indicate localized heating within cells 102 of the battery 100, the pressure signals may indicate internal gas accumulation, the voltage and current signals may reflect electrical instability, and the gas detection signals may indicate electrolyte decomposition or cell failure.
[0039] In an embodiment of the present invention, the sensing unit 202 may comprise acoustic sensors configured to detect acoustic emissions associated with internal structural changes, micro-crack formation, or internal faults within cells 102 of the battery 100. The acoustic sensor may provide early indication of potential cell failure.
[0040] In an embodiment of the present invention, the sensing unit 202 may comprise a temperature sensor, a pressure sensor, a voltage sensor, a current sensor, a gas detection sensor, and so forth. Embodiments of the present invention are intended to include or otherwise cover any sensors that may be encapsulated in the sensing unit 202, including known, related art, and/or later developed technologies.
[0041] In an embodiment of the present invention, the input interface 204 may be operatively coupled to the sensing unit 202 and adapted to receive the detected battery operating parameters. The input interface 204 may facilitate transmission of the operating parameters to downstream processing components. The input interface 204 may be, but not limited to, a wired communication interface, a wireless communication interface, a controller area network interface, a universal asynchronous receiver transmitter interface, a serial communication interface, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the input interface 204, including known, related art, and/or later developed technologies.
[0042] In an embodiment of the present invention, the received operating parameters may be transmitted to the input conditioning unit 206. The input conditioning unit 206 may be adapted to preprocess the received data to generate conditioned parameter data suitable for analysis. The preprocessing may include, but not limited to, noise reduction, signal filtering, normalization, scaling, or anomaly conditioning. Embodiments of the present invention are intended to include or otherwise cover any type of preprocessing techniques, including known, related art, and/or later developed technologies.
[0043] The input conditioning unit 206 may be, but not limited to, a signal conditioning circuit, a filtering unit, a normalization unit, a preprocessing unit, an analog-to-digital conversion unit, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the input conditioning unit 206, including known, related art, and/or later developed technologies.
[0044] In an embodiment of the present invention, the processing unit 208 may be operatively coupled to the input conditioning unit 206 and to the memory 210. The processing unit 208 may be configured to receive the detected battery operating parameters from the input conditioning unit 206. The processing unit 208 may be configured to analyse the conditioned parameter data using predictive models. The processing unit 208 may be configured to determine a likelihood of thermal runaway prior to ignition of the cell 102 of the battery 100. The processing unit 208 may be configured to generate control decisions based on the determined likelihood. The processing unit 208 may be configured to continuously update the likelihood of thermal runaway at predefined time intervals during operation of the battery 100. The processing unit 208 may be configured to select or adapt a predictive model based on battery usage patterns, charging conditions, or environmental operating conditions.
[0045] In an embodiment of the present invention, the processing unit 208 may be configured to implement artificial intelligence-based predictive analysis using machine learning models stored in the memory 210. The processing unit 208 may be adapted to analyze historical and real-time operating parameters of the battery 100, including temperature, voltage, current, pressure, and gas emission patterns, to identify abnormal operating conditions. The processing unit 208 may be further configured to train, update, or refine predictive models based on operating history, usage patterns, and environmental conditions to improve prediction accuracy. The processing unit 208 may generate predictive control decisions to initiate fire suppression prior to occurrence of thermal runaway.
[0046] In an embodiment of the present invention, the processing unit 208 may be operatively coupled with a battery management system associated with the battery 100. The processing unit 208 may receive battery management data including charging profiles, discharging profiles, voltage fluctuations, and current variations. The processing unit 208 may analyze the battery management data in conjunction with detected operating parameters to determine abnormal behavior of the battery 100 and predict likelihood of thermal runaway.
[0047] The processing unit 208 may be, but not limited to, a microprocessor, a microcontroller, a central processing unit, a digital signal processor, a field programmable gate array processor, an application specific integrated circuit processor, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the processing unit 208, including known, related art, and/or later developed technologies. The processing unit 208 may further be explained in detail in conjunction with FIG. 3.
[0048] According to embodiments of the present invention, the memory 210 may store the computer programmable instructions in form of programming modules. The memory 210 may be a non-transitory storage medium, in an embodiment of the present invention. The memory 210 may communicate with the processor 210 and execute a computer-readable set of instructions present in memory 210, in an embodiment of the present invention. The memory 210 may be, but not limited to, a Random-Access Memory (RAM), a Static Random-access Memory (SRAM), a Dynamic Random-access Memory (DRAM), a Read Only Memory (ROM), an Erasable Programmable Read-only Memory (EPROM), an Electrically Erasable Programmable Read-only Memory (EEPROM), a NAND Flash, a Secure Digital (SD) memory, a cache memory, a Hard Disk Drive (HDD), a Solid-State Drive (SSD) and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the memory 210, including known, related art, and/or later developed technologies.
[0049] The control decisions generated by the processing unit 208 may be transmitted to the output conditioning unit 212. The output conditioning unit 212 may be configured to format the generated control decisions into actuation control signals suitable for triggering protective actions within the battery 100. The output conditioning unit 212 may be, but not limited to, a signal formatting unit, a signal conditioning circuit, a voltage conditioning unit, a digital-to-analog conversion unit, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the output conditioning unit 212, including known, related art, and/or later developed technologies.
[0050] In an embodiment of the present invention, the formatted actuation control signals may be transmitted through the output interface 214. The output interface 214 may be, but not limited to, a wired interface, a wireless interface, a controller area network interface, a relay interface, a switching interface, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the output interface 214, including known, related art, and/or later developed technologies.
[0051] In an embodiment of the present invention, the fire-suppressant micro-capsules 216 may be disposed within or between the cells 102 of the battery 100. The fire-suppressant micro-capsules 216 may be operatively coupled to the output interface 214. The fire-suppressant micro-capsules 216 may be adapted to rupture in response to the actuation control signals or upon reaching a predefined thermal threshold, to release a fire-suppressant agent to suppress thermal runaway at the cell level.
[0052] In an embodiment of the present invention, the fire-suppressant micro-capsules 216 may contain a fire-suppressant agent selected from a group comprising fluoro-ketone-based suppressant agents, phosphate-based suppressant agents, inert gas suppressant agents, dry powder suppressant agents, non-conductive liquid suppressant agents, and combinations thereof. The fire-suppressant agent may be configured to suppress combustion, absorb heat, and prevent propagation of thermal runaway within the battery 100.
[0053] In an embodiment of the present invention, the fire-suppressant micro-capsules 216 may be configured to rupture automatically upon detection of a predefined thermal threshold within a range of 120 degrees Celsius to 180 degrees Celsius. The fire-suppressant micro-capsules 216 may additionally or alternatively be configured to rupture in response to actuation control signals generated by the processing unit 208.
[0054] In an embodiment of the present invention, the fire-suppressant micro-capsules 216 may be replaceable or replenishable during maintenance of the battery 100. The replaceable configuration may allow restoration of fire suppression capability following activation of fire-suppressant micro-capsules 216.
[0055] The fire-suppressant micro-capsules 216 may be, but not limited to, thermally activated suppressant capsules, electronically triggered suppressant capsules, polymer-coated suppressant capsules, gel-based suppressant capsules, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the fire-suppressant micro-capsules 216, including known, related art, and/or later developed technologies.
[0056] In an embodiment of the present invention, the containment unit 218 may be adapted to isolate the cell 102 of the battery 100 after release of the fire-suppressant agent to prevent propagation of heat and flame to adjacent cells 102 of the battery 100. In an embodiment of the present invention, the containment unit 218 may be adapted to isolate an affected cell of the battery 100 after release of the fire-suppressant agent. The containment unit 218 may restrict heat transfer and flame propagation to adjacent cells of the battery 100 to limit cascading failure within the battery 100. In an embodiment of the present invention, the containment unit 218 may comprise a self-sealing containment material configured to isolate an affected cell 102 of the battery 100 following release of the fire-suppressant agent. The containment unit 218 may comprise expandable fire-resistant gel materials, flame-retardant coatings, ceramic isolation materials, or combinations thereof. The containment unit 218 may prevent propagation of heat, flame, and thermal runaway to adjacent cells 102 of the battery 100.
[0057] The containment unit 218 may be, but not limited to, a thermal barrier, a ceramic containment structure, a flame-retardant barrier, a self-sealing containment structure, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the containment unit 218, including known, related art, and/or later developed technologies.
[0058] In an embodiment of the present invention, the cooling unit 220 may be configured to reduce temperature of the battery 100 following detection of abnormal operating conditions. The cooling unit 220 may comprise micro cooling channels, phase-change cooling materials, heat absorbing materials, or combinations thereof. The cooling unit 220 may be configured to absorb excess thermal energy from cells 102 of the battery 100 to prevent propagation of thermal runaway.
[0059] In an embodiment of the present invention, the venting unit 222 may be configured to direct gases released from cells 102 of the battery 100 toward a designated venting path. The venting unit 222 may reduce internal pressure and prevent structural damage or explosion of the battery 100. The venting unit 222 may operate automatically in response to abnormal operating conditions or actuation control signals generated by the processing unit 208.
[0060] In an embodiment of the present invention, the alert unit 224 may be adapted to generate a local or remote alert when abnormal conditions or a predicted thermal runaway event is identified. In another embodiment of the present invention, the alert unit 224 may be adapted to generate a local or remote alert when the determined likelihood of thermal runaway exceeds the predefined threshold. The alert may support real-time monitoring, maintenance intervention, or emergency response. In an embodiment of the present invention, the alert unit 224 may be configured to transmit alert signals to a remote monitoring system through a wireless communication network. The alert unit 224 may enable remote monitoring, diagnostics, and emergency response associated with abnormal operating conditions of the battery 100. The alert unit 224 may be, but not limited to, an audible alert device, a visual alert device, a wireless notification unit, a display unit, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the alert unit 224, including known, related art, and/or later developed technologies.
[0061] In an embodiment of the present invention, the system 200 may be powered by a power supply unit 226 configured to provide regulated electrical power to the sensing unit 202, the input interface 204, the input conditioning unit 206, the processing unit 208, the output conditioning unit 212, the output interface 214, and to the alert unit 224. The power supply unit 226 may draw power from the battery 100 itself or from an auxiliary power source. The power supply unit 226 may be, but not limited to, a battery power source, an auxiliary power source, a regulated power supply, a voltage regulator unit, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the power supply unit 226, including known, related art, and/or later developed technologies.
[0062] FIG. 3 illustrates components of the processing unit 208 of the system 200, according to an embodiment of the present invention. The processing unit 208 may comprise a parameter analysis module 300, a predictive analysis module 302, and a suppression control module 304.
[0063] In an embodiment of the present invention, the parameter analysis module 300 may be configured to receive conditioned parameter data from the input conditioning unit 206. The parameter analysis module 300 may be adapted to analyze battery operating parameters associated with cells 102 of the battery 100. The battery operating parameters may comprise temperature parameters, voltage parameters, current parameters, pressure parameters, gas emission parameters, and acoustic emission parameters.
[0064] The parameter analysis module 300 may be configured to identify abnormal variations, deviations, or trends in the battery operating parameters that may indicate unsafe operating conditions. The parameter analysis module 300 may generate analyzed parameter data representing detected abnormal operating conditions and transmit the analyzed parameter data to the predictive analysis module 302.
[0065] In an embodiment of the present invention, the predictive analysis module 302 may be configured to receive the analyzed parameter data from the parameter analysis module 300. The predictive analysis module 302 may implement artificial intelligence-based predictive models stored in the memory 210 to determine a likelihood of thermal runaway associated with cells 102 of the battery 100.
[0066] The predictive analysis module 302 may be configured to analyze real-time operating parameters and historical operating parameters of the battery 100 to identify patterns associated with thermal instability. The predictive analysis module 302 may further utilize machine learning algorithms configured to learn from historical battery performance data, failure data, and environmental conditions to improve prediction accuracy.
[0067] The predictive analysis module 302 may generate prediction data representing the likelihood, severity, and location of a potential thermal runaway event. The predictive analysis module 302 may transmit the prediction data to the suppression control module 304.
[0068] In an embodiment of the present invention, the suppression control module 304 may be configured to receive the prediction data from the predictive analysis module 302. The suppression control module 304 may be adapted to generate actuation control signals in response to the determined likelihood of thermal runaway.
[0069] The suppression control module 304 may transmit the actuation control signals to the output conditioning unit 212 and the output interface 214 to initiate release of a fire-suppressant agent from fire-suppressant micro-capsules 216 disposed within the battery 100.
[0070] The suppression control module 304 may further be configured to activate the containment unit 218, the cooling unit 220, and to the venting unit 222 to isolate affected cells 102, reduce thermal energy, and safely release gases from the battery 100.
[0071] In an embodiment of the present invention, the processing unit 208 may be configured to continuously update predictive models stored in the memory 210 based on newly received battery operating parameters. The processing unit 208 may improve prediction accuracy over time by adapting to battery usage patterns, environmental conditions, and aging characteristics of the battery 100. Embodiments of the present invention are intended to include or otherwise cover any type of processing unit 208 configured to analyze battery operating parameters, predict thermal runaway, and initiate fire suppression and containment actions, including known, related art, and/or later developed technologies.
[0072] FIG. 4 depicts a flowchart of a method 400 for detection, prediction and suppression of fire in the battery 100, according to an embodiment of the present invention.
[0073] At step 402, the system 200 may detect the battery operating parameters using the sensing unit 202.
[0074] At step 404, the system 200 may receive the detected battery operating parameters through the input interface 204.
[0075] At step 406, the system 200 may preprocess the received battery operating parameters through the input conditioning unit 206 to perform noise filtering, normalization, and anomaly conditioning to generate the conditioned parameter data.
[0076] At step 408, the system 200 may preprocess the conditioned parameter data to analyze the abnormal battery behavior.
[0077] At step 410, the system 200 may predict the likelihood of the thermal runaway prior to ignition of the cell 102 of the battery 100.
[0078] At step 412, the system 200 may generate the actuation control signals based on the predicted likelihood of thermal runaway.
[0079] At step 414, the system 200 may release the fire-suppressant agent disposed within or between the cells 102 of the battery 100 in response to the actuation control signals or upon reaching the predefined thermal threshold.
[0080] At step 416, the system 200 may isolate the affected cells 102 using the containment unit 218 to prevent propagation of heat and flame to the adjacent cells 120.
[0081] At step 418, the system 200 may reduce thermal energy of the battery 100 using the cooling unit 224 to absorb heat and limit propagation of the thermal runaway.
[0082] At step 420, the system 200 may vent gases released from the battery 100 using the venting unit 226 to reduce internal pressure and prevent structural damage or explosion of the battery 100. , Claims:CLAIMS
I/We Claim:
1. A system (200) for early detection, prediction and suppression of thermal runaway in a battery (100), the system (200) comprising:
sensing unit (202) disposed at a cell level and a module level within the battery (100), the sensing unit (202) being adapted to detect battery operating parameters comprising temperature, pressure, electrical characteristics, and gas emissions indicative of abnormal battery behavior;
an input interface (204) operatively coupled to the sensing unit (202) and adapted to receive detected battery operating parameters;
an input conditioning unit (206) adapted to preprocess the received battery operating parameters by performing noise filtering, normalization, and anomaly conditioning to generate conditioned parameter data; and
a processing unit (208) operatively coupled to the input conditioning unit (206) and a memory (210) storing executable instructions, characterized in that the processing unit (208) is configured to:
receive the detected battery operating parameters from the input conditioning unit (206);
analyse the conditioned parameter data using predictive models;
determine a likelihood of thermal runaway prior to ignition of cells (102a-102n) of the battery (100); and
generate control decisions based on the determined likelihood.
2. The system (200) as claimed in claim 1, comprising an output conditioning unit (212) configured to format the generated control decisions into actuation control signals.
3. The system (200) as claimed in claim 1, comprising an output interface (214) configured to transmit the actuation control signals.
4. The system (200) as claimed in claim 1, comprising fire-suppressant micro-capsules (216), disposed within or between the cells (102a-102n) of the battery (100) and operatively coupled to the output interface (214), adapted to rupture in response to the actuation control signals or upon reaching a predefined thermal threshold, to release a fire-suppressant agent to suppress thermal runaway at a cell level.
5. The system (200) as claimed in claim 1, comprising a containment unit (218) adapted to isolate the cells (102a-102n) of the battery (100) after release of the fire-suppressant agent to prevent propagation of heat and flame to adjacent cells (102a-102n) of the battery (100).
6. The system (200) as claimed in claim 1, wherein the sensing unit (202) comprises a temperature sensor, a pressure sensor, a voltage sensor, a current sensor, a gas detection sensor, or a combination thereof.
7. The system (200) as claimed in claim 1, wherein the processing unit (208) is configured to select or adapt a predictive model based on battery usage patterns, charging conditions, or environmental operating conditions.
8. The system (200) as claimed in claim 1, wherein the processing unit (208) is configured to continuously update the likelihood of thermal runaway at predefined time intervals during battery operation.
9. The system (200) as claimed in claim 1, comprising an alert unit (220) configured to generate a local or remote alert when the determined likelihood of thermal runaway exceeds a predefined threshold.
10. A method (400) for early detection, prediction, and suppression of thermal runaway in the battery (100), the method (400) is characterized by steps of:
detecting battery operating parameters, using sensing unit (202) disposed at a cell level and a module level within the battery (100);
receiving the detected battery operating parameters through an input interface (204);
pre-processing the received battery operating parameters using an input conditioning unit (206) to perform noise filtering, normalization, and anomaly conditioning to generate conditioned parameter data;
processing, using a processing unit (208) coupled to a memory (210) storing executable instructions, the conditioned parameter data to analyse abnormal battery behaviour;
predicting, using the processing unit (208), a likelihood of thermal runaway prior to ignition of cells (102a-102n) of the battery (100);
generating actuation control signals based on the predicted likelihood of thermal runaway;
releasing a fire-suppressant agent from fire-suppressant micro-capsules (216) disposed within or between the cells (102a-102n) of the battery in response to the actuation control signals or upon reaching a predefined thermal threshold;
isolating affected cells (102a–102n) using a containment unit (218) to prevent propagation of heat and flame to adjacent cells;
reducing thermal energy of the battery (100) using a cooling unit (220) configured to absorb heat and limit propagation of thermal runaway; and
venting gases released from the battery (100) using a venting unit (222) to reduce internal pressure and prevent structural damage or explosion of the battery (100).

Date: February 25, 2026
Place: Noida

Nainsi Rastogi
Patent Agent (IN/PA-2372)
Agent for the Applicant