Description:FORM 2
THE PATENTS ACT, 1970
[39 of 1970]
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(Section 10; Rule 13)

A SYSTEM AND METHOD FOR IMPROVING BATTERY SAFETY BY PREVENTING FIRE AND EXPLOSION

ULTRAVIOLETTE AUTOMOTIVE PVT. LTD.
529-530, Intermediate Ring Road, Domlur,
Bangalore – 560071, Karnataka, India
An Indian Company

The following specification particularly describes the invention and the manner in which it is to be performed.
FIELD OF THE INVENTION
The embodiments of the present disclosure relate generally to battery safety and particularly to prevent fire and explosion in lithium-ion batteries.

BACKGROUND OF THE INVENTION
Battery packs consist of thousands of cells packed together with several interconnects. Lithium-ion batteries are one of the most widely used batteries, and they play a significant role in the battery industry. Each of these battery cells convert the chemical energy of the substances it stores into electrical energy. Lithium batteries are sensitive to high temperatures, and they are inherently capable of catching fire. Heat also plays a role in degrading a Lithium-ion battery faster than normal. Lithium batteries are generally safe and unlikely to fail, but only so long as there are no defects, and the batteries are not damaged. When lithium batteries fail to operate safely or are damaged, they may present a fire and/or explosion hazard. Once alight, the battery pack fires can burn very fiercely, and common fire suppressants don't work.

In recent years, with the automobile industry growing rapidly, the electronic devices that are mounted on automobiles have increased significantly. Most of these electronic devices include printed circuit board assemblies. The printed circuit boards have been used for various reasons and one of the main usages is for Battery Management System (BMS). Battery Management System (BMS) is designed to monitor the parameters connected with the battery pack and its individual cells, then use the data collected to reduce safety problems and ensure battery performance. The parameters include temperature, humidity, hydrogen etc. BMS manages battery optimization via cell balance, which increases the battery's long-term life. The BMS can also monitor the voltage, coolant flow, state of charge (SOC) and state of health (SOH), of the battery pack. Most electric automobiles are powered by lithium-ion batteries with a high charge density. As a result, these batteries should never be overcharged or allowed to reach a deep discharge state. Thermal runaway arises when the current running through the battery during charging or overcharging causes the temperature of the cell to rise. Issues like these can shorten the battery's life or reduce its capacity and lead to hazardous conditions such as smoke, overheating, short circuit, fire etc. to the vehicle.

PROBLEM TO BE SOLVED BY INVENTION
During a thermal runaway, the heat generated by a failed cell can move to the next cell, causing it to become thermally unstable as well. Once a battery cell fails, it is impossible to control the failed cell as the chemical reaction inside the cell happens far too quickly. This chain reaction can cause the entire pack to be destroyed within a few short seconds and lithium-ion battery fires are very hard to extinguish.

Hence, it is a primary objective of the current invention to solve the problem of thermal runaway by ensuring that the failed cell does not cause the cells around it to also fail and provide much better safety.

Also, in case of failure of a cell or thermal runaway, the users might not be aware of the battery status thus putting users and bystanders lives at risk. Thus, it is another objective of the current invention to detect the failure in battery pack at an early stage and provide the status of the same to the users with alerts. This plays a vital role as it allows the users to step away from the vehicle thereby avoiding injuries or saving lives.

Further, the battery packs catching fire and exploding lead to complete damage of the vehicles which is a huge loss to cover and waste of resources involved. Thus, it is yet another objective of the current invention to avoid such loss and wastage.

The above-mentioned shortcomings, disadvantages and problems are addressed herein and which will be understood by reading and studying the following specification.

SUMMARY OF THE INVENTION
Various embodiments herein describe a system and method for improving battery safety by preventing fire and explosion. According to an embodiment of the present invention, a system for improving battery safety by preventing fire and explosion is disclosed. A battery module includes one or more battery cells encapsulated with flame-retardant barrier that are placed at predetermined distance from each other to prevent transfer of heat from one battery cell to another. The encapsulated one or more battery cells fail in the battery module due to internal short circuit, the said failure resulting in thermal runaway. A plurality of sensors detect the failed one or more battery cells. A battery management system (BMS) receives the detected signals from the plurality of sensors. The battery management system generates an alert based on the received signals. A vehicle control unit (VCU) receives the generated alert from the battery management system. The vehicle control unit sends command to the battery management system based on the received alert to turn-off power supply to a motor controller. The vehicle control unit routes the received alert to a display cluster and to a horn. The display cluster and the horn annunciates the routed alert.

According to another embodiment of the present invention, a method for improving battery safety by preventing fire and explosion is disclosed. The method disclosed is as follows. Encapsulating one or more battery cells in a battery module with flame-retardant barrier that are placed at predetermined distance from each other to prevent transfer of heat from one battery cell to another. Failure of the encapsulated one or more battery cells in the battery module due to internal short circuit, the said failure resulting in thermal runaway. Detecting the failed one or more battery cells by a plurality of sensors. Receiving the detected signals from the plurality of sensors by a battery management system (BMS). Generating an alert based on the received signals by the battery management system. Receiving the generated alert from the battery management system by a vehicle control unit (VCU). Sending command to the battery management system based on the received alert to turn-off power supply to a motor controller by the vehicle control unit. Routing the received alert to a display cluster and to a horn by the vehicle control unit. Annunciation of the routed alert by the display cluster and the horn.

As per first embodiment of the current invention, the generated alert may be a visual or an audio.

As per second embodiment of the current invention, the method comprises absorbing of heat by a battery enclosure to prevent fire and explosion.

As per third embodiment of the current invention, the method comprises releasing of smoke by one or more vents present on the battery enclosure to prevent fire and explosion.

As per fourth embodiment of the current invention, the method comprises releasing of pressure by one or more vents that open under high pressure conditions in the battery enclosure.

As per fifth embodiment of the current invention, the method comprises absorbing of heat by a metal core printed circuit board (MCPCB) to prevent fire and explosion.

As per sixth embodiment of the current invention, the method comprises isolating the short-circuited one or more battery cells from other battery cells by one or more fuses to prevent fire and explosion.

As per seventh embodiment of the current invention, the flame-retardant barrier comprises of any one or more of the following materials such as but not limited to polyurethane, silicone, ceramic glass fibres, phase change material, epoxy or chemical compounds.

As per eighth embodiment of the current invention, the system comprises a battery enclosure for absorbing of heat to prevent fire and explosion.

As per ninth embodiment of the current invention, the system comprises one or more vents present on the battery enclosure for releasing of smoke to prevent fire and explosion.

As per tenth embodiment of the current invention, the system comprises a metal core printed circuit board (MCPCB) for absorbing of heat to prevent fire and explosion.

As per eleventh embodiment of the current invention, the system comprises one or more fuses for isolating the short-circuited one or more battery cells from other battery cells to prevent fire and explosion.

The foregoing has outlined, in general, the various aspects of the invention and serves as an aid to better understanding the more complete detailed description which is to follow. In reference to such, there is to be a clear understanding that the present invention is not limited to the method or application of use described and illustrated herein. It is intended that any other advantages and objects of the present invention that become apparent or obvious from the detailed description or illustrations contained herein are within the scope of the present invention.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The other objects, features and advantages will occur to those skilled-in-the-art from the following description of the preferred embodiments and the accompanying drawings in which:

Figure 1 is a schematic diagram illustrating improving of battery safety by preventing fire and explosion, according to an embodiment of the present invention.

Figure 2 is a schematic block diagram illustrating improving of battery safety by preventing fire and explosion, according to an embodiment of the present invention.

Figure 3 is a schematic flow diagram illustrating improving of battery safety by preventing fire and explosion, according to an embodiment of the present invention.

Further, those skilled-in-the-art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a system and method for improving battery safety by preventing fire and explosion. In the following detailed description of the embodiments of the invention, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled-in-the-art to practice the invention, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.

The specification may refer to “an”, “one” or “some” embodiment(s) in several locations. This does not necessarily imply that each such reference is to the same embodiment(s), or that the feature only applies to a single embodiment. Single features of different embodiments may also be combined to provide other embodiments.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes”, “comprises”, “including” and/or “comprising” when used in this specification, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations and arrangements of one or more of the associated listed items.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Embodiments of the present invention will be described below in detail with reference to the accompanying figures.

According to Figure 1 and Figure 2, a system for improving battery safety by preventing fire and explosion is disclosed. A battery module (101) includes one or more battery cells (102) encapsulated with flame-retardant barrier (103) that are placed at predetermined distance from each other to prevent transfer of heat from one battery cell (102) to another. The encapsulated one or more battery cells (102) fail in the battery module (101) due to internal short circuit, the said failure resulting in thermal runaway. A plurality of sensors (104) detect the failed one or more battery cells (102). A battery management system (BMS) (105) receives the detected signals from the plurality of sensors (104). The battery management system (105) generates an alert based on the received signals. A vehicle control unit (VCU) (106) receives the generated alert from the battery management system (105). The vehicle control unit (106) sends command to the battery management system (105) based on the received alert to turn-off power supply to a motor controller (107). The vehicle control unit (106) routes the received alert to a display cluster (108) and to a horn (113). The display cluster (108) and the horn (113) annunciates or announces the routed alert.

According to Figure 3, a method for improving battery safety by preventing fire and explosion is disclosed. The method disclosed is as follows. Encapsulating one or more battery cells (102) in a battery module (101) with flame-retardant barrier (103) that are placed at predetermined distance from each other to prevent transfer of heat from one battery cell (102) to another. Failure of the encapsulated one or more battery cells (102) in the battery module (101) due to internal short circuit, the said failure resulting in thermal runaway. Detecting the failed one or more battery cells (102) by a plurality of sensors (104). Receiving the detected signals from the plurality of sensors (104) by a battery management system (BMS) (105). Generating an alert based on the received signals by the battery management system (105). Receiving the generated alert from the battery management system (105) by a vehicle control unit (VCU) (106). Sending command to the battery management system (105) based on the received alert to turn-off power supply to a motor controller (107) by the vehicle control unit (106). Routing the received alert to a display cluster (108) and to a horn (113) by the vehicle control unit (106). Annunciation of the routed alert by the display cluster (108) and the horn (113).

As per first embodiment of the current invention, the generated alert may be a visual or an audio.

As per second embodiment of the current invention, the method comprises absorbing of heat by a battery enclosure (109) to prevent fire and explosion.

As per third embodiment of the current invention, the method comprises releasing of smoke by one or more vents (110) present on the battery enclosure (109) to prevent fire and explosion.

As per fourth embodiment of the current invention, the method comprises releasing of pressure by one or more vents (110) that open under high pressure conditions in the battery enclosure (109).

As per fifth embodiment of the current invention, the method comprises absorbing of heat by a metal core printed circuit board (MCPCB) (111) to prevent fire and explosion.

As per sixth embodiment of the current invention, the method comprises isolating the short-circuited one or more battery cells (102) from other battery cells (102) by one or more fuses (112) to prevent fire and explosion.

As per seventh embodiment of the current invention, the flame-retardant barrier (103) comprises of any one or more of the following materials such as but not limited to polyurethane, silicone, ceramic glass fibres, phase change material, epoxy or chemical compounds.

As per eighth embodiment of the current invention, the system comprises a battery enclosure (109) for absorbing of heat to prevent fire and explosion.

As per ninth embodiment of the current invention, the system comprises one or more vents (110) present on the battery enclosure (109) for releasing of smoke to prevent fire and explosion.

As per tenth embodiment of the current invention, the system comprises a metal core printed circuit board (MCPCB) (111) for absorbing of heat to prevent fire and explosion.

As per eleventh embodiment of the current invention, the system comprises one or more fuses (112) for isolating the short-circuited one or more battery cells (102) from other battery cells (102) to prevent fire and explosion.

FURTHER ADVANTAGES OF THE INVENTION
The current invention solves the problem of thermal runaway by ensuring that the failed cell does not cause the cells around it to also fail and provide much better safety. The current invention also detects the failure in battery pack at an early stage and provides the status of the same to the users with alerts. This plays a vital role as it allows the users to step away from the vehicle thereby avoiding injuries or saving lives. The current invention also helps in avoiding loss and wastage.

Although the embodiments herein are described with various specific embodiments, it will be obvious for a person skilled in the art to practice the invention with modifications. However, all such modifications are deemed to be within the scope of the claims. It is also to be understood that the following claims are intended to cover all the generic and specific features of the embodiments described herein and all the statements of the scope of the embodiments which as a matter of language might be said to fall there between.

REFERENCE TABLE

S.No. Name Numbering
1. a battery module 101
2. one or more battery cells 102
3. flame-retardant barrier 103
4. a plurality of sensors 104
5. a battery management system (BMS) 105
6. a vehicle control unit (VCU) 106
7. a motor controller 107
8. a display cluster 108
9. a battery enclosure 109
10. one or more vents 110
11. a metal core printed circuit board (MCPCB) 111
12. one or more fuses 112
13. a horn 113
, C , Claims:CLAIMS

We claim:

1. A method for improving battery safety by preventing fire and explosion, the method comprising of:
encapsulating one or more battery cells (102) in a battery module (101) with flame-retardant barrier (103) that are placed at predetermined distance from each other to prevent transfer of heat from one battery cell (102) to another;
failure of the encapsulated one or more battery cells (102) in the battery module (101) due to internal short circuit, the said failure resulting in thermal runaway;
detecting the failed one or more battery cells (102) by a plurality of sensors (104);
receiving the detected signals from the plurality of sensors (104) by a battery management system (BMS) (105);
generating an alert based on the received signals by the battery management system (105);
receiving the generated alert from the battery management system (105) by a vehicle control unit (VCU) (106);
sending command to the battery management system (105) based on the received alert to turn-off power supply to a motor controller (107) by the vehicle control unit (106);
routing the received alert to a display cluster (108) and to a horn (113) by the vehicle control unit (106);
annunciation of the routed alert by the display cluster (108) and the horn (113).

2. The method as claimed in claim 1, wherein the generated alert may be a visual or an audio.

3. The method as claimed in claim 1, wherein the method comprises absorbing of heat by a battery enclosure (109) to prevent fire and explosion.

4. The method as claimed in claim 1, wherein the method comprises releasing of smoke by one or more vents (110) present on the battery enclosure (109) to prevent fire and explosion.

5. The method as claimed in claim 1, wherein the method comprises releasing of pressure by one or more vents (110) that open under high pressure conditions in the battery enclosure (109).

6. The method as claimed in claim 1, wherein the method comprises absorbing of heat by a metal core printed circuit board (MCPCB) (111) to prevent fire and explosion.

7. The method as claimed in claim 1, wherein the method comprises isolating the short-circuited one or more battery cells (102) from other battery cells (102) by one or more fuses (112) to prevent fire and explosion.

8. A system for improving battery safety by preventing fire and explosion, the system comprising of:
a battery module (101) includes one or more battery cells (102) encapsulated with flame-retardant barrier (103) that are placed at predetermined distance from each other to prevent transfer of heat from one battery cell (102) to another;
the encapsulated one or more battery cells (102) fail in the battery module (101) due to internal short circuit, the said failure resulting in thermal runaway;
a plurality of sensors (104) detect the failed one or more battery cells (102);
a battery management system (BMS) (105) receives the detected signals from the plurality of sensors (104);
the battery management system (105) generates an alert based on the received signals;
a vehicle control unit (VCU) (106) receives the generated alert from the battery management system (105);
the vehicle control unit (106) sends command to the battery management system (105) based on the received alert to turn-off power supply to a motor controller (107);
the vehicle control unit (106) routes the received alert to a display cluster (108) and to a horn (113);
the display cluster (108) and the horn (113) annunciates the routed alert.

9. The system as claimed in claim 8, wherein the flame-retardant barrier (103) comprises of any one or more of the following materials such as polyurethane, silicone, ceramic glass fibres, phase change material, epoxy or chemical compounds.

10. The system as claimed in claim 8, wherein the system comprises a battery enclosure (109) for absorbing of heat to prevent fire and explosion.

11. The system as claimed in claim 8, wherein the system comprises one or more vents (110) present on the battery enclosure (109) for releasing of smoke to prevent fire and explosion.

12. The system as claimed in claim 8, wherein the system comprises a metal core printed circuit board (MCPCB) (111) for absorbing of heat to prevent fire and explosion.

13. The system as claimed in claim 8, wherein the system comprises one or more fuses (112) for isolating the short-circuited one or more battery cells (102) from other battery cells (102) to prevent fire and explosion.