«2 United States Patent Hermann (S4)_ EARLY DETECTION OF BATTERY CELL, THERMAL EVENT Weston A. Hermann, Palo Alt, CA, (ws) (75) aventor: (73) Assignee: Tesla Motors Inc, Palo Alto, CA (US) (7) Notice: Subject o any disclaimer, the term ofthis, patent is extended or adjusted under 35 USC, 154(b) by 993 days (21) Appl.No 117820,660 (22) Filed: Jun. 20,2007 @) Prior Publication Data US 200810315839 A1 Dec, 25,2008 (1) Incl HOLM 200 (2006.01), (2) US. 429/61; 429/50; 429/88; 429/59, 429162; 4291112 (58) Fleld of Classification Search 429/50, 429158, 59,61, 62, 12 ‘See application file for complete search history 1US007939192B2 (1) Patent No: US 7,939,192 B2 (45) Date of Patent: May 10, 2011 6690991 B2 102003 Kitamura etal 6705101 B2 32004 Brot eta 6885298 BD 42005. Everson etal ‘T140'765 BD _ 12006 Memol ea 20020145346 A1* 102002 Sakakibara ove 20040137313 AL* 72004 Jara eal ‘29102 00810023267 AL* 22005 Timans etl 2i9.405 * cited by examiner Primary Examiner —Patick Ryan Ben Lewis Patent Law Office of David Assistant Examiner (74) Altornes, Agent, oF Firm G.Beck on A battery module for use in an electric vehicle is dislose Te battery modale includes a plurality of cell arranged ina predetermined pater withinthemodule, The battery module also includes an optical pyrometr arranged inside the mosl- ‘ule. The optical pyrometr installed within the module after being tune to detect a predetermine frequency or band of frequencies. The pyrometer wll be usedt detect an increase in shor wave radiation density from one ofthe battery cel ‘within the module wherein that battery cll has temperature above predetermined threshold. The optical pyrometer will, ‘be used to communicate an electric signal toa contol system, ofthe elecri vehicle wherein that control syste will imple ‘ment a predetermined mitigation process to contin the ther- ‘mal event ofthat one cell within the battery module, ABSTRACT 13 Claims, 4 Drawing Sheets +, QOO00GI00000 56) References Cited U.S, PATENT DOCUMENTS, 453.26 A 81985 Zhukov etal Sosa) A 101991 Hleyeseea uoToN v. Mesescecesese QOOOOTOOQQO QPL JIG IIIO GO00US. Patent May 10, 2011 Sheet 1 of 4 US 7,939,192 B2SY: SSB. Zeeeooe® ODDITIIIIO ACW quayed *S'N 7 TI'GEGL SAquayed *S'N 1107 ‘or dew P50 ¢ aus 7 TI'GEGL SA90999999998 Dae FRLLERLLLLLD QOOOOOOQOOO [fs of 59-5 [ ACW quayed *S'N 7 TI'GEGL SAUS 7,939, 1 BARLY DETECTION OF BATTERY CELL, ‘THERMAL EVENT BACKGROUND OF THE INVENTION 1. Feld of the Invention The subject invention generally relates to detection of @ ‘thermal even and more particularly relates to early detection ‘ofa battery cell thermal event within batery module for use inan electric vehicle vo 2, Description of Related An itis well known i the prior art to use electric automobiles to provide transportation for occupants. Many ofthese prior an electric automobiles camry several thousand pounds of ‘nickel meal hydride bateries to achievea long range electric vehicle for every day use by consumers. Furtemore, many ofthese prior art eloctricweicles noo tobe physically large ‘and heavy to accommodate all ofthese batteries, such that these ears are not capable of achieving necessary aceelera- tion, handling, performance and an extended range needed for an electric cat to become a feasible option for public purchase and use. Many prior at eletrical vehicles are of ‘normal size and not overly heavy ina very smal range, thus reducing feasibility for large mass selling of such vehicles to the consuming public. Furthermore, many of these prior art 2 clectrc vehicles which use such batteries had problems with frotecting the oocupans inthe vehicle from the high voltage ‘components and high temperatures that emanate from such high voltage components and sill provide vehicle that trv lsat acceptable speeds comparable to that ofa gasoline or icsel intemal combustion engine. Maay of these prior art. electrical vehicles have had problems with the prior art bat- teries overheating, thus redvcing the range of the electric vehicle, the durability and overall ie ofthe batteries ar cell that are part of the batery pack systems within the eletric vehicle Generally, the battery or ells arranged within many prior an vehicles operate with high power output which ineeases the temperature and hence, may reduce the longevity ofthese prior art batteries. The use ofthe heavy and high voltage batteries systems ofthe prirart electric cars required alot of ‘maintenance to Keep the batteries operating due tothe high temperatures at which the battery pack systems operated Some of these priorart systems tried to maximizelongevity of the btteriesby usingairevoled systems that would blow cold 4s air over the batteries and remove unnecessary heat from the battery compartment. Some other systems use other cooling techniques to ty and keep 2 consistent temperature forthe ‘battery cells and averall batery pack within these prioe act. systems. Generally, in many ofthese prior at vehicles if one cell ofthe battery overheats, such overheating of one cell may propagate to suroundiags cells thus creating thermal ran away event for he battery pack of the electric vehicle, How= ever, some ofthese prior at systems were able wo detet the ‘overheating of individual cells within the battery packer @ combustion event occurs and then iiate mitigation of such thermal runaway events, Therefore, the earlier the detection ‘ofa thermal event ofan individual ell within a battery mol tule, the more effective the mitigation process would be to prevent anal out thermal runaway event forthe battery mod 6 le, ‘Therefore, there isa nood in the art fr an improved early detection process for a battery cll having a thermal event within a battery module. There also isa need ia the at foran improved apparatus fr detecting thermal events at an earlier 6 ‘ime than prorat systems. Thee also isa need inthe art for ‘an early detection thermal eveat system that uses an optical 192 B2 2 pyrometer to determine if battery cell has a temperature agreaterthana predetermined threshold. Therealsoisncedia the at for an early detection system that wil increase the ‘maximum longevity, efciency and power that can be extract from the battery cells within a battery mode thus increasing the range ofan electri vehicle forthe consumer. ‘There also is a need in the art for @ thermal event early detection system that will allow for early intervention via mitigation processes such a fll active cooling of battery module or decreasing the power demand from the suround- ing cells of a runaway'cel SUMMARY OF THE INVENTION One object ofthe present invention may be to provide an improved early detection system fora battery cell thermal event Another object ofthe present invention may be to provide ‘an early detection system for use in an eles veil, Another object ofthe present invention may be to provide thermal event early detection system that uses an optical pyrometer arranged within a battery module Sill another object of the present invention may be to provide @ thermal event early detection system that uses reflective surlaces arranged at predetermined positions within a battery module ‘Yet anaer objet of the present invention may be to pro vide a themnal event detection system using & plurality of optical pyometers arranged therein Sill another object of the present invention may be to provide thermal event early detection system tats capable ‘of detecting one battery cell wit a high temperature wherein, self heating is beginning and mitigating such high tempera ture before al stored energy is released as heat from the cll. Sill nother object of the present invention may be to provide thermal event early detection system that iscapable ‘of having an optical pyromiter tuned toa singe frequency or ‘anarow band of feequencies wherein such frequency sens tivity i selected for each predetermined battery module and associated cals, Sill another object of the present iaveation may be to use ‘anelecionic signal fram the pyromter to monitor the radia. tion enemy density over a chosen range of frequencies via a ‘contro system and then initiating mitigation measuresto stop ‘the propagation of thermal runaway within the entire battery module ‘Toachieve the foregoing objects abarery module foruse in ‘an electric vehicle having a plurality of cells aranged in a predetermined patter within the module is disclosed. The Fattery module further includes an optical pyeometer amanged inside the module for detecting thermal snaway of ‘one of the cells to ensure mitigation processes may prevent the entire battery module from entering thermal runaway and propagating thereto, One aavantage of the present invention may be that it provides a novel and improved thermal event early detetion system. Sill a further advantage ofthe present invention may be thatit provides a themmal event early detection system for use inan elecec vehicle, ‘Yet another advantage ofthe present invention may be that it provides for use of an optical pyrometer within a battery module for ealy detection of @ thermal event in a single battery cel, Sill another advantage ofthe present invention may be tht it provides for use ofa rlletve surface within a bateryUS 7,939, 3 ‘mole to decrease the absomption and transmission of inka ‘el radiation at and through the outer walls ofthe module. Sill another advantage ofthe present invention is that it ‘may provide forthe use of reflective surfaces to direc the Howe of infra radiation within the module. 5 Sill another advantage ofthe present invention may be that ‘ach cell within the module may be seen by the pyrometer within the battery module; ‘means for optically monitoring emissions within sad bat- ‘ery module and within a predetermined wavelength band, wherein said means for optically monitoringemi sons outputs first signal when said emissions within said battery module and within seid predetermined ‘wavelength band exceed predetenmined threshold; cooling system thermally coupled to said battery module, wherein said cooling system is configured to actively «vol std battery module; and ‘acontrol system coupled to said means for optically moni ‘oring emissions and coupled to ssid cooling system, ‘wherein said control system activates said cooling sys- ‘emupon receipt of sid fist signal fom sid means for optically monitoring emissions. 2. The battery module of claim 1 wherein sid plurality of cells further comprise reflective outer surices contigured to reflect approximately 95% of photons within said predeter- mined wavelength band. 3. The battery module of elaim 1 wherein said means for ‘optically monitoring emissions further comprises an optical Pyrometer 4, The battery module of claim 1 wherein seid prodeter- ‘mined threshold coeresponds to cell temperature of is approximately 100°C. 8 192 B2 10 5. The battery module of claim 1 wherein said contol system reducescurrent demand from atleast a portion of sid pluclty of cells within the battery module upon receipt of sui first signal from ssid means for optically monitoring 6, The battery module of claim 1 wherein said cans for ‘optieally monitoring emissions further comprises a plurality of optical pyromerers arranged within the batery module 7. The battery module of elaim 1 further comprising a plurality of reflective surfaces arranged within said batery ‘module, wherein said plurality of reflctive surfaces reflect ‘photons within sad predetermined wavelength ban. 8. The batery module of claim 7 wherein said plurality of reflective surfaces exhibit lower radiation absorption and ‘wansmission within suid predetermined wavelength band than a plurality of inner battery module surfaces. 9. The battery module of claim 7 wherein sid plurality of refletve surfaces direct photons withia suid predetermined ‘wavelength band loward suid means foropteally monitoring 10, A method of detecting a battery cell thermal event within a battery module of an electric vehicle, said method. inchuding the steps ‘monitoring optical emissions within aid battery module and within a predetermined wavelength band ‘comparing optical emissions monitored within ssid hatory ‘module and within said predetemnined wavelength band w apredetermined threshold; outputting fis signal when sid optical emissions moni ‘ored within said battery module and within sid prede~ termined wavelength baad exceed suid predetermined thresholds ‘wansmiting said first signal to contol system; and activating a cooling system thermally coupled to sid bat- tery module when sud contol system receives sai fist signal 11. The method of claim 10 wherein sad predetermined threshold eomesponds toa cell temperature of approximately 10°, 12. The method of claim 10 further comprising the step of arranging plurality of reflective surfaces within sid battery ‘modileto decrease losses via absorption and transmission of radiation within said prodetermiaed wavelength band ‘through atleast one wall of the batery module, 13. The method of claim 10 further comprising the step of redvcing curent demand from a plurality of battery cells ‘within said battery module when said control system receives, sid ist signal