Cell Balancing Algorithms to Prevent Thermal Runaway in EVs

Multifunctional battery packaging and insulation system that enables efficient cooling of lithium-ion battery cells through a novel porous ceramic foam structure. The system comprises a block with strategically positioned recesses that house individual battery cells, where the foam material has open cells allowing gas or liquid flow. A pump circulates cooling media through the block, enabling precise temperature management and preventing thermal runaway. The system addresses both thermal management and cell-level cooling challenges in lithium-ion battery cells.

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Balancing protection for multiple series-connected battery cells through real-time monitoring of voltage, current, and temperature data. The system analyzes internal resistance gradients to predict potential degradation and thermal issues, enabling targeted balancing interventions. It integrates temperature and resistance data to evaluate the impact of thermal management strategies on battery performance. The system employs machine learning algorithms to optimize balancing operations based on real-time data, ensuring consistent voltage and temperature distribution across the battery pack.

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A battery module with adaptive coolant channel cross-sectional area control to mitigate thermal runaway events in lithium-ion cells. The module features heat-sinks with variable coolant channel cross-sectional areas that dynamically adjust to maintain optimal cooling performance based on temperature changes in adjacent cells. This adaptive cooling strategy prevents thermal runaway propagation by redirecting cooling to affected cells, thereby preventing the thermal runaway event from spreading throughout the module.

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Battery management system that prevents temperature-related degradation in lithium-ion batteries by controlling cell temperature differences through real-time monitoring and predictive maintenance. The system measures temperature at two points in the battery pack, one at each cell, and compares them to predict potential temperature imbalances. Based on this temperature comparison, the system implements temperature-controlled charging or discharging strategies to prevent thermal stress on cells operating at different temperatures.

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A battery pack thermal runaway protection system that uses advanced cell-level data analysis to prevent thermal runaway in battery packs. The system integrates a battery management system (BMS) with a thermal management system to monitor and control temperature and voltage conditions across the battery pack. When abnormal conditions are detected, the BMS sends control signals to the thermal management system, which activates targeted cooling through precise flow management of the cooling medium. This enables rapid temperature reduction and prevents the rapid thermal runaway that can occur when cells fail to cool properly. The system incorporates multiple temperature sensors and flow control mechanisms to ensure uniform cooling across the battery pack.

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A BMS system for lithium-ion battery packs that prevents thermal runaway through active control of individual cells. The system comprises multiple sub-control circuits connected in parallel to the main control chip, each controlling a separate battery cell. The sub-control circuits employ a ferrite bead filter to remove high-frequency interference, and a light-emitting diode to monitor temperature. The system integrates a varistor-based equalization module and a temperature control module, with the sub-control circuits controlling each cell individually. This configuration enables precise temperature management of each battery cell while preventing thermal runaway across the entire pack.

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Energy storage system optimization through dynamic equalization control that balances charging time and energy loss. The system employs an optimization algorithm to find the optimal charging rate and time based on real-time conditions, including temperature, battery state, and load demand. This approach enables precise control of the charging process while minimizing energy loss through advanced equalization strategies that combine passive and active methods. The system continuously monitors energy loss and adjusts the equalization parameters to maintain optimal performance and battery lifespan.

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A battery pack discharge method to mitigate thermal runaway and reduce safety risks when cells overheat. The method involves selectively discharging bypass cells and monitoring cell voltages to prevent thermal runaway propagation. When a cell temperature exceeds a threshold, find physically connected bypass cells and discharge them to lower pack voltage. This reduces the chance of neighboring cells overheating. Similarly, if a cell voltage exceeds a threshold, discharge it to lower pack voltage. This prevents adjacent cells from overcharging. By selectively discharging cells, it reduces the pack's overall voltage to mitigate thermal runaway and reduces safety risks.

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Delaying or preventing heat propagation in high voltage battery packs with cell stacks having thermal barrier layers between cells. The technique involves reducing the state of charge of adjacent cells if a cell experiences thermal runaway. This targeted discharge removes energy that could trigger further propagation in adjacent cells. The discharge time is coordinated with the thermal delay provided by the barrier layer to maximize the discharge window. By combining barrier layers with controlled cell discharge, safety is balanced with energy density.

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Battery cell unit, battery pack, and vehicle technology that enhance safety by preventing thermal runaway through advanced thermal management systems. The system integrates multiple thermal monitoring and protection mechanisms across the battery pack, including temperature sensors, thermal management systems, and protective circuitry. This integrated approach enables real-time detection and response to thermal anomalies, preventing catastrophic failures and ensuring the safe operation of the battery pack and vehicle.

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A method for equalizing the state of charge (SOC) of cascaded battery clusters in energy storage systems through advanced control strategies. The method involves determining the standard deviation of battery cell voltage across the entire system, then employing automatic bypass control to dynamically adjust the SOC of non-bypassed clusters during charging and discharging phases. This approach ensures consistent SOC levels across all clusters, mitigating the common issue of SOC imbalance in cascaded systems.

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Battery pack for power storage devices that rapidly extinguishes thermal runaway in battery cells through controlled external short-circuiting. The pack comprises a housing, battery modules with integrated thermal management, and an external short-circuiting unit that rapidly connects to a battery cell when thermal runaway occurs. The external short-circuiting unit enables controlled external discharge of the short-circuited cell, preventing spread of thermal energy through the pack. This enables rapid fire suppression and prevention of thermal runaway, significantly improving safety in battery packs.

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Battery Management System (BMS) for electric vehicles that ensures balanced charging across all cells while preventing overcharging. The system employs a unique switching strategy that dynamically distributes charge between cells, utilizing a combination of ultra-capacitor (UC) charging and natural charging control. The BMS employs a thermistor-based temperature monitoring system and temperature-controlled charging profiles to maintain consistent state-of-charge across all battery cells.

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Battery system and control method that prevents cell balancing errors by dynamically identifying and balancing abnormal cells. The system monitors battery cell parameters and detects cells with significant deviations from normal operation. When an abnormal cell is detected, the system calculates a reference voltage for balancing the affected cells, ensuring uniform voltage and state-of-charge across the battery module. This approach enables precise balancing while avoiding the limitations of traditional passive balancing methods.

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Non-level active and passive equalization circuit for lithium-ion battery packs that achieves precise balancing through dynamic threshold-based control. The circuit employs an LC resonant circuit with three capacitors and an active equalization circuit based on MOSFET switches, while a passive equalization circuit uses a resistance shunt. The circuit extracts dynamic thresholds from battery characteristics like voltage, SOC, and ambient temperature, and dynamically switches between active and passive equalization modes to achieve balance.

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Thermal runaway prevention system for series-connected battery packs that prevents overheating while maintaining pack operation. The system employs a multi-layer thermal management approach: a high thermal conductivity layer surrounding each battery cell, a low thermal conductivity material filling the gaps between these layers, and a heat pipe connecting the layers. Temperature sensors monitor each layer's temperature, and a series branch switch controls the cell or branch while a parallel branch switch controls the spare cell. The system prevents heat migration through the layers by using low thermal conductivity materials to block heat transfer between cells, and the heat pipe facilitates efficient heat dissipation. This configuration enables real-time temperature monitoring and automatic temperature control of each cell while maintaining pack operation.

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Early warning method for thermal runaway of power batteries that addresses the current limitations of traditional methods. The method employs a novel approach to detect thermal runaway by analyzing the difference between the battery's internal resistance and its thermal resistance. This difference is calculated based on the battery's temperature and internal resistance, providing a more accurate indication of potential thermal runaway compared to traditional methods that rely solely on temperature thresholds.

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Control method, device, and battery pack technical field for preventing thermal runaway spread in lithium-ion battery packs. The method involves a distributed control system that monitors battery temperature and voltage changes across the pack. When a battery's temperature or voltage exceeds predetermined thresholds, the system automatically activates temperature-controlled switches in adjacent batteries, preventing the spread of thermal runaway. This approach enables localized cooling and containment of thermal events, rather than relying on centralized cooling systems that can be ineffective in preventing the spread of thermal runaway.

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Accumulator for electric vehicles with enhanced thermal management capabilities. The accumulator comprises a series or parallel arrangement of battery cells connected by cooling plates, with integrated emergency cooling devices. Each cooling plate features a temperature-sensing element and a controlled flow system for managing coolant or refrigerant during thermal events. The emergency cooling devices prevent thermal spread between cells by selectively activating cooling when internal cell temperatures exceed predetermined thresholds. This integrated cooling system enables safe operation of high-voltage batteries with enhanced thermal stability.

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Active temperature equalization control for battery packs during cooling to prevent severe temperature fluctuations and improve thermal consistency, efficiency, and safety. The system monitors the average and maximum temperature differences between sensors in the pack. It then adjusts fan and pump speeds to stepwise change the coolant inlet temperature. This reduces the large initial temperature difference between hot pack and cold coolant, preventing excessive temperature swings and internal damage.

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