BATTERY PACK CONFIGURED TO DETERMINE A DEFORMATION EVENT

Systems and methods are provided for determining a deformation event in a battery pack. The battery pack may comprise a conductive path coupled to a first electrical connector and a second electrical connector. Processing circuitry may be configured to detect a change in an electrical characteristic of the conductive path indicating a transition from a first circuit state of the conductive path to a second circuit state of the conductive path. The processing circuitry may be configured to determine, in response to the detecting, a deformation event in the battery pack.

INTRODUCTION

Electric vehicles include battery packs. Battery packs can perform a number of functions, including providing a protective enclosure to withstand impacts, routing of electrical wires, and containment in the event of a battery fire.

Electric vehicles can be subjected to a wide range of operating environments. For example, electric adventure vehicles are being encouraged to be driven in off-road environments. Such electric vehicles are exposed to rough terrain, as well as water fording scenarios. In some situations, these environments may expose the battery pack to damage and may puncture the pack structure. Continuing to use an electric vehicle with battery pack damage or a puncture can lead to further damage from, for example, contaminants entering the battery pack structure.

SUMMARY

Accordingly, described herein are systems, methods and apparatuses configured to determine or diagnose a deformation event in a battery pack. The battery pack may comprise a conductive path coupled to a first electrical connector and a second electrical connector. The battery pack may comprise processing circuitry configured to detect a change in an electrical characteristic of the conductive path indicating a transition from a first circuit state of the conductive path to a second circuit state of the conductive path. The processing circuitry may determine, in response to the detecting, a deformation event in the battery pack. In some embodiments,

In some embodiments, the processing circuitry is configured to detect the change in the electrical characteristic based on a signal received via the first and second electrical connectors. In some embodiments, the first circuit state is a closed circuit state of the conductive path and the second circuit state is an open circuit state of the conductive path. In some embodiments, the first circuit state is an open circuit state of the conductive path and the second circuit state is a closed circuit state of the conductive path.

In some embodiments, the first and second electrical connectors comprise first and second pogo pins. In some embodiments, the battery pack may comprise at least one layer, and the conductive path comprises a continuous loop of conductive material embedded in the at least one layer. The conductive path may be coupled to the first pogo pin via a first contact pad, and the conductive path may be coupled to the second pogo pin via a second contact pad. The conductive path may be coupled to the processing circuitry via the first pogo pin and the second pogo pin.

In some embodiments, the conductive path comprises a first separate loop of conductive material, and a second separate loop of conductive material. The processing circuitry may be configured to detect a change in the electrical characteristic of the conductive path by detecting the change in the electrical characteristic of the first separate loop of conductive material or by detecting the change in the electrical characteristic of the second separate loop of conductive material.

In some embodiments, the conductive path comprises a first separate loop of conductive material, a second separate loop of conductive material, a third separate loop of conductive material, and a fourth separate loop of conductive material. The processing circuitry may configured to detect the change in the electrical characteristic of the conductive path by detecting changes in the electrical characteristic of the first separate loop of conductive material and the third separate loop of conductive material; or the first separate loop of conductive material and the fourth separate loop of conductive material; or the second separate loop of conductive material and the third separate loop of conductive material; or the second separate loop of conductive material and the separate fourth separate loop of conductive material.

In some embodiments, the processing circuitry is configured to detect the change in the electrical characteristic of the conductive path by determining, based on an output signal of a digital flip-flop, a transition from a first state of the digital flip-flop to a second state of the digital flip-flop.

In some embodiments, the battery pack comprises an upper layer, a lower layer, and a middle layer disposed between the upper layer and the lower layer, the middle layer comprising the conductive path.

In some embodiments, the processing circuitry is configured to detect the change in the electrical characteristic of the conductive path by determining that the electrical characteristic exceeds a threshold amount.

In some embodiments, the processing circuitry is the processing circuitry is further configured to cause a notification to be generated for display, at a display of an electric vehicle, wherein the notification comprises an indication that the battery pack is damaged by a puncture or a bend, and the deformation event comprises the puncture or the bend.

In some embodiments, the processing circuitry is further configured to, in response to determining the deformation event in the battery pack, determine, based on sensor data received from an isolation leakage sensor, whether isolation leakage is present. The processing circuitry may, in response to determining the presence of the isolation leakage, generate for output, at a display of an electric vehicle, a notification indicating the presence of the isolation leakage.

In some embodiments, the processing circuitry is further configured to determine, based on sensor data, that water is present in the battery pack, and cause a notification to be generated for display, at a display of an electric vehicle, based on the determination that water is present and the determination of the deformation event.

In some embodiments, systems and methods are provided for implementing the battery pack. In some embodiments, a non-transitory computer-readable medium is provided having non-transitory computer-readable instructions encoded thereon that, when executed by a processor, cause the processor to detect a change in an electrical characteristic of a conductive path coupled to a first and a second electrical connector, the change indicating a transition from a first circuit state of the conductive path to a second circuit state of the conductive path, or indicating a transition from an open circuit state of the conductive path to a closed circuit state of the conductive path; and determine, in response to the detecting, a deformation event in the battery pack.

DETAILED DESCRIPTION

The present disclosure is directed to techniques for determining a deformation event in a battery pack.FIG.1illustrates isometric exploded views of an exemplary battery pack100, in accordance with some embodiments of the disclosure. As shown on the left side ofFIG.1, battery pack100may comprise one or more of top lid102, frame104, bottom plate or bottom layer106, and strike plate or skid plate108. Top lid102may be positioned above frame104and may be affixed thereto, bottom layer106may be positioned below frame104and may be affixed thereto, and skid plate108may be positioned below bottom layer106and may be affixed thereto. Any suitable technique may be used to bond the layers of battery pack100(e.g., adhesive, spot welding, mechanical fasteners). In some embodiments, battery pack100is an electric vehicle battery pack.

As shown on the right side ofFIG.1, skid plate108may optionally comprise top layer110nearest bottom layer106and affixed thereto when battery pack100is assembled. Middle layer112may be attached to top layer110and bottom layer114of skid plate108. Skid plate108may be implemented in a similar manner as is discussed in more detail in connection with commonly owned U.S. application Ser. No. 16/682,738 to Sekar et al., filed Nov. 13, 2019 and published as US 2020/0152927 A1, the contents of which is incorporated by reference herein in its entirety.

In some embodiments, one or more of top lid102, frame104, bottom layer106, and skid plate108may be a composite layer. Top lid102may comprise carbon laminate having layers of carbon fibers and/or glass laminate having layers of glass fibers, with steel elements affixed to portions of a top surface thereof. Frame104may comprise extruded aluminum and may further comprise die cast aluminum affixed to side portions thereof. In some embodiments, bottom plate106may comprise carbon laminate and/or glass laminate and may comprise any suitable number of stacked layers (e.g.,15). Additionally or alternatively, bottom plate106may include one or more layers comprising metals or alloys thereof (e.g., aluminum and/or steel layers). The carbon laminate may comprise any suitable combination of fiber orientation, e.g., bottom layers of bottom plate106may have a negative orientation (e.g., −45°), top layers of bottom plate106may have a positive orientation (e.g., 90°), or one or more of the layers may have a 0° fiber angle.

FIG.2shows an exemplary arrangement of a layer of a battery pack100, in accordance with some embodiments of the disclosure. Bottom layer106of battery pack100may comprise layers202(e.g., an upper carbon fiber layer), layer204and layer206(e.g., a lower carbon fiber layer). Layer204of bottom layer106may comprise conductive path222which may correspond to a conductive wire or trace (e.g., copper and/or conductive carbon fiber and/or a metallic film or any other suitable conductive material or any combination thereof) embedded and/or molded and/or wet pressed in any suitable material (e.g., carbon fiber, cloth, plastic, paper, or any other suitable material or any combination thereof). Bottom layer106may be manufactured using any suitable technique. In some embodiments, bottom layer106may be manufactured by providing a plurality of layers (e.g., of carbon fiber, and/or any other suitable material) where one layer (e.g., layer204) may contain conductive path222.

In some embodiments, electrical connector215and electrical connector217(e.g., pogo pins, one-piece connectors, plugs, sockets, probes, pins, magnetic connectors and/or any other suitable electrical connector) may be coupled to conductive path222, e.g., directly or by way of contact pads211,213(e.g., comprising for example, graphite foil or copper mesh or copper lamella). Any suitable number of electrical connectors may be employed in the configuration ofFIG.2. In some embodiments, once layer106is formed, one side of layer204may be machined (e.g., through layer202) to expose contact pads211and213, and when layer204is attached to frame104, electrical connectors215,217(e.g., spring-loaded pogo pins) may make spring contact with the contact pads211and213. In some embodiments, contact pads211,213may be secured to conductive path222by way of a crimping technique. In some embodiments, milling may be performed on an underside of the embedding material in a vicinity of contact pads211,213.

In some embodiments, conductive path222may comprise a conductive loop starting at contact pad211(e.g., a sense mat ribbon), meandering through one or more area regions of bottom layer106and ending at contact pad213, e.g., located proximate contact pad211. Conductive path222may be coupled to printed circuit board (PCB)216(e.g., configured to be in communication with, and/or implement at least in part, a battery management system (BMS)502) by way of electrical connectors215,217having respective spring contacts218. In some embodiments, electrical connector215,217may be coupled to BMS502by way of spring contacts218and/or one or more wires shown inFIG.2. In some embodiments, sealant or epoxy214may be employed to affix PCB216to upper layer202of layer106. In some embodiments, electrical connectors215,217may be spring-loaded connectors implemented as one of a variety of types of configurations (e.g., through-hole design, surface mount design, barrel crimp, solder cup, or any combination thereof), which may be useful as blind mating connectors.

As shown inFIG.2, electrical connector215, electrical connector217, wiring to BMS502and/or any suitable portions of BMS502, any suitable portion(s) of bottom layer106, any suitable housing, PCB216, epoxy214, and/or any other suitable component, or any combination thereof, may be considered as part of a puncture sensor210. In some embodiments, puncture sensor210may be configured to detect a break in a wire forming conductive path222. In some embodiments, conductive path222and/or contact pads211,213may be considered separate from puncture sensor210. Alternatively, conductive path222and/or contact pads211,213may be considered to form at least a part of puncture sensor210. In some embodiments, circuitry of PCB216, and/or BMS502(which may be electrically coupled to PCB216, electrical connector215and217, contact pads211and213and conductive path222), may be configured detect a change in one or more electrical characteristics (e.g., resistance, voltage, current) of conductive path222, and determine the occurrence of a deformation event (e.g., a puncture of battery pack100or a deformation or bend of battery pack100) based on the detected one or more changed electrical characteristics. For example, if a breach of battery pack100occurs (e.g., based on the underside of the electric vehicle striking a rock, the ground or other terrain, or an object breaching battery pack100), conductive path222may be broken and caused to transition from a first circuit state (e.g., a closed circuit state) to a second circuit state (e.g., an open circuit state), causing a change in resistance of the conductive path222, and a deformation event may be detected. In some embodiments, PCB216(e.g., configured to implement, or otherwise be in communication with BMS502) may be located within battery pack100, or alternately may be located at another location within the electric vehicle of battery pack100. While in this example conductive path222is shown disposed at layer204between layers202and206, it should be appreciated that conductive path222may be disposed at any portion of battery pack100(e.g., at one or more of layers202or206or any other suitable location, such as for example, in any of the layers shown inFIG.1).

FIG.3shows an exemplary arrangement of frame104of a battery pack100, in accordance with some embodiments of the disclosure. Frame104may provide structural rigidity and strength to withstand impact and protect battery modules accommodated (e.g., at portions310) in a battery pack100, which may be positioned, for example, in a bottom portion of an electric vehicle under the vehicle cabin. For example, any suitable number of battery modules (e.g.,8) may be positioned and secured within the frame104and may be configured to provide electrical power to operate an electric vehicle. For example, eight rectangular battery modules may be included in battery pack100, and may each include one or more (e.g., two) layers of battery cells. In some embodiments, bottom plate106of battery pack100may be directly exposed to the exterior environment of the vehicle, e.g., and may function as a structural element of the vehicle. In some embodiments, one or more intervening components (e.g., skid plate108, shield drivetrain components) may be installed between at least a portion of bottom plate106and the exterior environment. It may be desirable for bottom plate106and/or skid plate108to provide particular structural characteristics, such as long-term resistance to forces incurred during driving as well as blunt forces such as ground strikes.

As shown inFIG.3, frame104may comprise side retaining members302, front retaining member304, rear retaining member306, and cross members308. Side retaining members302may extend along opposite outer sides of frame104to form a peripheral shape of frame104, and a plurality of cross members308may transversely extend in parallel to each other between side retaining members302. Such arrangement of cross members308may create a number of channels therebetween to form portions or areas310for the installation of battery modules, although any suitable arrangement may be utilized. In some embodiments, opposite ends of each cross member308may connected to each side retaining member302in any suitable manner (e.g., via brackets and fasteners) that provides sufficient strength for the resulting frame104to protect electric batteries therein in the event of vehicle impact and provide suitable attachment points for other components of the vehicle. Frame104may be at least partially open and comprise a variety of points for ingress and egress of relevant components. In some embodiments, side retaining members302, front retaining member304, rear retaining member306, and cross members308may each be machined or otherwise acted upon in any manner, to accommodate any other structures within the battery pack, e.g., to include a center cutout proximate to surfaces thereof, to accommodate structures such busbars. Connection area312may correspond to a portion of battery pack100at which puncture sensor210contact (e.g., implementing or otherwise coupling puncture sensor210to BMS502), and/or at which electrical connectors215and217contact PCB216.

FIG.4shows an exemplary sensing area402associated with conductive path222of a battery pack100, in accordance with some embodiments of the disclosure. Sensing area402is represented by the dashed boundary lines ofFIG.4. Conductive path222, which may correspond to a conductive wire or trace (e.g., copper and/or conductive carbon fiber and/or a metallic film or any other suitable conductive material) embedded and/or molded and/or wet pressed in any suitable material (e.g., carbon fiber, cloth, plastic, paper and connected to such material by way of, for example, graphite foil or copper mesh or copper lamella), may be provided in the form of a continuous loop in bottom layer106, positioned below frame104. In the example ofFIG.4, the loop of conductive path222may form sensing area402surrounding a perimeter of bottom layer106and/or frame104. For example, the continuous loop of conductive path222may traverse back and forth between the boundary of area402from one end to the other to provide even coverage of the sensing area. In some embodiments, less than an entire perimeter of bottom layer106and/or frame104may be encompassed by the loop of conductive path222and/or the loop of conductive path222may comprise multiple separate loops of conductive trace or one or more portions of any other suitable sensor configuration. Material404extending past the perimeter of frame104may represent portions of bottom layer106having been machined out or otherwise removed from bottom layer106during fabrication of battery pack100.

FIG.5shows an exemplary arrangement of a layer of a battery pack100, in accordance with some embodiments of the disclosure. As shown inFIG.5, conductive path222may be integrated in, and/or exposed on, bottom layer106, e.g., in the form of a sensing mat, pad and/or loop (e.g., a conductive loop of oxygen free copper, coated with silver, of any suitable thickness and width). In some embodiments, each of the positive and negative electrodes of conductive path222may end in a same general area508(e.g., 10 mm apart or any other suitable distance apart). Conductive path222may be a continuous conductive loop of any suitable pattern, and may be coupled to electrical connectors215,217directly or via contact pads211,213(not shown inFIG.5). Electrical connectors215,217may comprise metallic connectors configured to extend to respective contact pads211,213, to electrically couple conductive path222and BMS502. In some embodiments, BMS502may correspond to, or otherwise comprise or be a part of, a high voltage distribution box (HVDB), which may comprise a negative HVDB terminal504. In some embodiments, puncture sensor210may be disposed or mounted, at least in part, at negative terminal504of the HVDB and electrically connected thereto.

In some embodiments, electrical connectors215,217may be spring loaded against bottom plate106such that the electrical connectors215,217remain secured to bottom plate106even if battery pack100is exposed to vibrations or other forces during driving of the electric vehicle. For example, pogo pins can be used as electrical connectors215,217to handle additional loading in shocks and vibrations. Another benefit of using pogo pins as electrical connectors215,217is that they can accommodate a large tolerance stack up between puncture sensor210and bottom plate106with respect to handling different distances due to part-to-part variation, e.g., as part of a manufacturing or assembling process. In some embodiments, BMS502may be configured to detect whether an electrical characteristic of conductive path222changes, and determine the occurrence of a deformation event based on such detection, e.g., based on an electrical signal received by way of electrical connectors215,217. In some embodiments, puncture sensor210may be positioned at least in part at the negative HVDB terminal of BMS502shown inFIG.5. In some embodiments, the manufacturing process of bottom layer106may comprise forming multiple layers of bottom layer106and machining holes into a top portion thereof to reach respective contact pads211,213(not shown) interfacing with each electrical connector215,217. Contact pads211,213may be provided with extra thickness to provide tolerance for the machining process, and at least a portion of the contacts pads may be machined out to provide for a connection between the contact pads and electrical connectors215,217.

FIG.6shows an exemplary sensing areas602associated with a conductive path222of a battery pack100, in accordance with some embodiments of the disclosure. Sensing areas602are represented by the dashed lines ofFIG.6. Sensing areas602comprise a plurality of regions each having respective continuous loops of conductive path222. Each region may correspond to a position where a battery module may be accommodated in frame104. In some embodiments, sensing areas602may not extend under structural cross members308. For example, in some circumstances, a deformation event occurrence of a deformation or puncture under structural components such as cross member308may be less concerning because such damage may be unlikely to impact the battery modules and operation of battery pack100. In some embodiments, the region under cross members308may include separate conductive paths and/or puncture sensors. In some embodiments, these conductive paths and/or puncture sensors may be associated with a different sensitivity (e.g., a lower sensitivity to detect more severe deformation events).

FIG.7shows exemplary sensing areas associated with a conductive path222of a battery pack, in accordance with some embodiments of the disclosure. As shown inFIG.7, conductive path222may correspond to a plurality of separate conductive paths or conductive loops706,708,710,712and714, respectively spanning in various vertical and horizontal directions of bottom layer106, which may be positioned below frame104(e.g., directly below or separated by one or more other layers of bottom layer106). Thus, sensing region702may be divided into a plurality of regions (e.g.,6or any other suitable number of regions) to enable pinpointing a location at which a deformation event has occurred. For example, if an object strikes battery pack100(e.g., while the electric vehicle is traveling off-road) and punctures or otherwise deforms battery pack100, BMS502may detect this occurrence (e.g., based on a change in resistance of conductive path222, such as detecting a particular circuit state (e.g., an open circuit condition) associated with conductive path222for at least a brief period of time) and determine that the deformation occurrence corresponds to position704within a particular region on an underside of battery pack100. Position704of the deformation event may be indicative of a change in resistance in, e.g., conductive path706and conductive path712. The deformation event may be detected based on a change in an electrical characteristic in any suitable combination of the separate conductive loops (e.g., changes detected in separate loops706and712or changes detected in separate loops706and714; or changes detected in separate loops708and712or changes detected in separate loops708and714; or changes detected in separate loops710and712or changes detected in separate loops710and714). For example, at least two changes in electrical characteristics may be detected (e.g., at one of separate conductive loops706,708, or710, and at one of separate conductive loops712or714) to enable pinpointing of the location of the deformation event.

The arrangement ofFIG.7may also enable BMS502and/or service technicians examining battery pack100to quickly confirm where the deformation event occurred (e.g., at a particular battery module that may be associated with the deformation event). Any suitable number of conductive paths and/or sensors can be used to increase or decrease the resolution of detecting a location where the damage occurred. In some embodiments, a mesh style conductive wire may be utilized as conductive path222in the example ofFIG.7. In some embodiments, any suitable mesh density may be selected for each of conductive loops706,708,710,712and714, and/or conductive loops706,708,710,712and714may each be arranged to traverse region702, e.g., go back and forth across region702, any suitable number of times.

FIG.8shows an exemplary configuration of a conductive path, in accordance with some embodiments of the disclosure. Conductive path222may comprise conductive layers802and806(e.g., a plastic laminate having a metal or alloy thereof applied thereon) having space therebetween such that the circuit is normally in a first circuit state (e.g., an open circuit state). Object808(e.g., a nail or other conductive object) may strike battery pack100(e.g., while the electric vehicle is traveling off-road) and puncture or otherwise deform battery pack100, and if object808contacts one or more of conductive layers802and806, BMS502may detect the change or transition of the state of conductive path222from a first circuit state (e.g., an open circuit state) to a second circuit state (e.g., a closed circuit state), and determine a deformation event based on such detected change.

FIG.9shows a system900comprising electric vehicle901, in accordance with some embodiments of this disclosure. Vehicle901may be a car (e.g., a coupe, a sedan, a truck, an SUV, a bus), a motorcycle, an aircraft (e.g., a drone), a watercraft (e.g., a boat), or any other type of vehicle or any combination thereof. Electric vehicle901may comprise processing circuitry902which may comprise processor904and memory905. Processor904may comprise a hardware processor, a software processor (e.g., a processor emulated using a virtual machine), or any combination thereof. In some embodiments, processor904and memory905in combination may be referred to as processing circuitry902of vehicle901. In some embodiments, processor904alone may be referred to as processing circuitry902of vehicle901. Memory905may comprise hardware elements for non-transitory storage of commands or instructions, that, when executed by processor904, cause processor904to operate vehicle901in accordance with embodiments described above and below. Processing circuitry902may be communicatively connected to components of vehicle901and system900via one or more wires, or via wireless connection. In some embodiments, memory905may be configured to store electronic data, computer software, or firmware, and may include random-access memory, read-only memory, hard drives, optical drives, solid state devices, or any other suitable fixed or removable storage devices, and/or any combination of the same. Nonvolatile memory may also be used (e.g., to launch a boot-up routine and other instructions). In some embodiments, processing circuitry902may include or be in communication with other processing circuitry in vehicle901(e.g., an electronic control unit (ECU) of vehicle901, which may be configured to communicate with other portions of vehicle901and perform various tasks). For example, in some embodiments, BMS502and/or processing circuitry902of battery pack100, or functionality thereof, can be included as part of other components of electric vehicle901, such as an ECU of vehicle901.

In some embodiments, processing circuitry902may include any suitable circuitry for processing signals received from puncture sensor210(e.g., via one or more electrical connectors215,217). For example, processing circuitry902may include signal conditioning circuitry (e.g., filters, amplifiers, voltage dividers), an analog to digital converter, any other suitable circuitry, or any combination thereof. Processing circuitry902may, in some embodiments, include a processor, a power supply, power management components (e.g., relays, filters, voltage regulators, differential amplifiers), input/output IO (e.g., GPIO, analog, digital), memory, communications equipment (e.g., CANbus hardware, Modbus hardware, or a WiFi module), any other suitable components, or any combination thereof. In some embodiments, processing circuitry902may include one or more microprocessors, microcontrollers, digital signal processors, programmable logic devices, field programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), etc., and may include a multi-core processor. In some embodiments, processing circuitry902may be distributed across multiple separate processors or processing units, for example, multiple of the same type of processing units or multiple different processors.

Processing circuitry902may be communicatively connected to electric battery910, which may be configured to provide power to one or more of the components of vehicle901during operation. In some embodiments, vehicle901may be an electric vehicle or a hybrid electric vehicle. Electric battery910may include one or more battery modules. In some embodiments, battery910may be a 180 kWh battery pack or a 135 kWh battery pack. Processing circuitry902may manage the flow of electricity to electric battery910(e.g., to perform AC-DC conversion when battery910is charged with an AC charger), and any other suitable components. Processing circuitry902may be configured to manage charging of battery910, which may include measuring one or more characteristics of battery910, identifying if a fault has occurred (e.g., in battery910or in battery pack100), providing power to components of vehicle901, communicating with a battery charger, any other suitable actions, or any combination thereof. Processing circuitry902may include or monitor, for example, electrical components (e.g., switches, bus bars, resistors, capacitors), control circuitry (e.g., for controlling suitable electrical components), and measurement equipment (e.g., to measure voltage, current, impedance, frequency, temperature, or another parameter). Processing circuitry902may determine charge status information e.g., charge level, whether the battery is being charged, charging current, charging voltage, charging mode, and whether a charging fault exists. Processing circuitry902and/or BMS502may be configured to determine the occurrence of a deformation event.

Processing circuitry902may further include communications circuitry906and input/output (I/O) circuitry908. I/O circuitry908may be communicatively connected to display912and speaker914by way of I/O circuitry908. Display912may be located at a dashboard of vehicle901and/or a heads-up display at a windshield of vehicle901. For example, a notification regarding the determination of a deformation event may be generated for display, and display912may comprise an LCD display, an OLED display, an LED display, or any other type of display. In some embodiments, display912may provide an operator and/or passenger of electric vehicle901with an indication recommending servicing of vehicle901based on the deformation event. Speaker914may be located at any location within the cabin of vehicle901, e.g., at the dashboard of vehicle901, on an interior portion of the vehicle door. In some embodiments, speaker914may be configured to provide audio alerts to notify an operator and/or passenger of electric vehicle901of the determined deformation event. In some embodiments, haptic alerts may be provided to notify an operator and/or passenger of electric vehicle901of the determined deformation event. In some embodiments, alerts may be provided to user device918(e.g., a mobile device, such as, for example, a smartphone or a tablet or a key fob, such as via wireless or wired communication), in addition to or alternative to display912and speaker914within electric vehicle901. In some embodiments, the notification may include an indication of a recommendation that electric vehicle901avoid water fording activities.

I/O circuitry908may be in communication with puncture sensor210and/or conductive path222(e.g., disposed in bottom layer106of battery pack100), to enable processing circuitry902to monitor puncture sensor210and/or conductive path222and determine the occurrence of a deformation event. I/O circuitry908may also be in communication with isolation loss sensor916. Isolation loss sensor916may monitor isolation resistance as between high-voltage components of vehicle901and chassis ground. For example, if a deformation event is detected, and subsequently isolation loss is detected by isolation loss sensor916, processing circuitry902may cause a notification to be generated for output (e.g., at vehicle display912and/or vehicle speaker914and/or at user device918). For example, isolation loss may be detected based on a detected leakage current exceeding a threshold.

In some embodiments, a water sensor922may be included in electric vehicle901, e.g., to determine whether water is present in or around battery pack100. For example, water sensor922may detect the presence of water based on measuring a decreased resistance between two electrodes, e.g., based on the electrical conductivity of water. In some embodiments, sensor data generated by water sensor922may be used in determining whether a deformation event has occurred, and/or may be used in generating notifications to the driver regarding the detected water (e.g., indicating a leak in battery pack100). For example, processing circuitry902may cause a notification to be generated for display, at display912and/or a display of user device918, based on the determination that water is present (as indicated by water sensor922) and the determination of the deformation event (as indicated by puncture sensor210). In some embodiments, a load threshold of battery pack100may be determined, and data related to an amount of force applied to the battery pack100(e.g., due to a ground strike or being struck by a rock while driving) may be communicated to service scheduling system920and/or provided as a notification to display912or otherwise communicated to the operator of electric vehicle901. For example, processing circuitry902may determine the likelihood of a deformation or puncture at least in part based on the load data.

In some embodiments, in determining the occurrence of a deformation event, processing circuitry902may consider the output of puncture sensor210(and/or the changed electrical characteristic associated with conductive path222) in conjunction with one or more other sensor signals, e.g., isolation loss sensor916and/or water sensor922and/or any other suitable sensors of other suitable sources of information. For example, processing circuitry902may determine a confidence score with respect to the occurrence of a deformation event based on such inputs. An alert level of an alert, to be generated for display and/or generated for output to speaker914and/or to be transmitted to service scheduling system920and/or user device918, may be determined based upon such confidence score. For example, a lower level alert may be provided if only one of the outputs of puncture sensor210, isolation loss sensor916and water sensor922suggest a deformation event has occurred, which may result in a relatively low confidence score. On the other hand, a higher level alert may be provided if two of such sensor outputs suggests that a deformation event has occurred, which may result in a relatively higher confidence score. In some embodiments, an urgent notification may be provided for a very high confidence score (e.g., if all three of such sensor outputs suggest the occurrence of a deformation event), and/or BMS502may take corrective action, e.g., reducing current levels within battery pack100.

In some embodiments, processing circuitry902may be in communication (e.g., via communications circuitry906) with user device918(e.g., a mobile device, a computer, a key fob, etc.). Such connection may be wired or wireless. In some embodiments, communications circuitry906and/or user device918may be in communication with a service scheduling system920(e.g., over a communications network such as, for example, the Internet, and/or a cellular telephone network and/or a satellite network and/or any other suitable network or communication technique), to communicate with a service technician entity (e.g., servers associated with the entity or an operator associated with the entity) regarding the determined deformation event. In some embodiments, data related to the deformation event may be automatically transmitted to such service technician entity.

It should be appreciated thatFIG.9only shows some of the components of vehicle901, and it will be understood that vehicle901also includes other elements commonly found in vehicles (e.g., electric vehicles), e.g., a motor, brakes, wheels, wheel controls, turn signals, windows, doors, etc.

FIG.10shows a block diagram1000of circuitry of battery pack100, in accordance with some embodiments of this disclosure. In some embodiments, the circuitry discussed in connection withFIG.10may be included as part of, or may be otherwise in communication with, processing circuitry902ofFIG.9and/or BMS502.

As shown inFIG.10, puncture sensor210(and/or conductive path222) may be connected to high voltage protection circuitry1001,1002, e.g., one or more IC chips comprising MOSFETs in combination with one or more resistors1004, e.g., to diagnose a short to ground condition associated with puncture sensor210(and/or conductive path222). High voltage protection circuitry1001,1002may be configured to protect against power surges and electrostatic damage caused by faults by limiting voltage and/or current across the circuit. Constant voltage or current source1006may be configured to output a constant voltage or constant current to puncture sensor210(and/or conductive path222). In some embodiments, constant voltage or current source1006may employ a low dropout regulator circuit to regulate a voltage applied to puncture sensor210(and/or conductive path222). The current received by puncture sensor210(and/or conductive path222) from constant source1006may be configured to flow from a first terminal of electrical connector215,217, through a conductive loop (e.g., as shown inFIG.5) to a second terminal of electrical connector215,217.

In some embodiments, one or more of input filter and/or signal conditioning circuitry1010,1011may be employed. For example, puncture sensor210(and/or conductive path222), current or voltage source1006and/or high voltage protection circuitry1001,1002may be coupled to one or more of input filter and/or signal conditioning circuitry1010,1011, which may comprise any suitable components configured to perform processing of signals received from prior stages of the circuitry and/or select signals of a particular frequency range, to facilitate further processing of the signals at later stages of the circuitry. In some embodiments, input filter and/or signal conditioning circuitry1010,1011may include, e.g., one or more of resistors, capacitors, inductors, operational amplifiers, transistors, ADC, DAC, differential amplifiers, Zener diodes, Schottky diodes, etc.

In some embodiments, voltage monitor1012may be employed, e.g., coupled to input filter and/or signal conditioning circuitry1010and/or high voltage protection circuitry1001and/or puncture sensor210(and/or conductive path222). Voltage monitor1012may employ any suitable number and types of components (e.g., one or more of a comparator, operational amplifier, differential amplifier, instrumental amplifier, voltage supervisor, flip-flop circuitry, latch circuitry, etc.). Voltage monitor1012may be configured to detect (at1018) a resistance change in puncture sensor210(and/or conductive path222), e.g., based on a transition from a first circuit state (e.g., an open circuit state or a closed circuit state) to a second circuit state (e.g., the open circuit state or closed circuit state, based on which the first circuit state), even if a rapid momentary change. In some embodiments, one or more signals output by voltage monitor1012may be undergo processing (e.g., analog to digital conversion) for input to processing circuitry902at1018. In some embodiments, voltage monitor1012may be configured to provide the functionality of an over voltage monitor, e.g., configured to limit or cut off voltage to prevent damage to electronic circuitry, and/or an under voltage monitor, e.g., configured to interrupt the circuit when a fault condition arises such as voltage below a preset level.

In some embodiments, voltage monitor1012may comprise an operational amplifier having two inputs (e.g., a negative feedback input and an input signal associated with puncture sensor210and/or conductive path222), where the output of the operational amplifier corresponds to the voltage or current difference between the inputs of the operational amplifier. The operational amplifier may be configured to amplify a voltage measurement to be output to BMS502to facilitate processing of the signal at BMS502. In some embodiments, such voltage measurement may be used in determining whether a resistance change has occurred, e.g., whether a deformation event has occurred with respect to battery pack100.

Circuitry1000may further comprise comparator1014, e.g., an operational amplifier configured to compare input signals and output a signal indicating which input signal is larger based on the comparison. Comparator1014may monitor one or more electrical characteristics (e.g., voltage, current, resistance) associated with puncture sensor210(and/or conductive path222) and compare such one or more monitored characteristics (e.g., an analog signals) to a threshold input value. For example, if comparator1014determines that the threshold input value exceeds a current of the puncture sensor210and/or conductive path222(e.g., even if for a transitory period), comparator1014may output to flip-flop circuit1016a signal (e.g., a digital signal) indicating this comparison result. For example, in an open circuit condition of puncture sensor210(and/or conductive path222), no current flows through puncture sensor210(and/or conductive path222) for a period of time. Accordingly, comparator1014may determine that a threshold value provided as input to comparator1014exceeds a signal that is input to comparator1014based on a reading of, e.g., zero amps of current flowing through puncture sensor210(and/or conductive path222) in the open circuit state.

Flip-flop circuit or latch1016may be a digital flip-flop or digital latch configured to be switched from a first stable output state to a second stable output state based on a trigger pulse received from comparator1014. The state of flip-flop circuit1016may be a function of prior received inputs and outputs, and flip-flop1016may be configured to store binary data and may provide one or two outputs. The output of flip-flop circuit1016may depend on the current input as well as the state of flip-flop circuit1016, and may be edge-triggered by a rising or falling edge of the pulse (e.g., synchronous or clocked) or level-triggered (e.g., asynchronous). Flip-flop circuit1016may be, e.g., a D flip-flop, an S-R flip-flop, a J-K flip-flop, a T flip-flop, or any combination thereof. In some embodiments, flip-flop circuit1016, upon receiving a signal from comparator1014indicative of an open circuit condition of puncture sensor210(and/or conductive path222), may output to BMS502a signal indicative to BMS502of a change of output state from one or more prior outputs of flip-flop circuit1016. BMS502may determine (at1020) on the basis of the signal received from flip-flop circuit1016that a trip or fault condition has occurred in puncture sensor210(and/or conductive path222). It should be appreciated that the open circuit detection mechanism and voltage reading mechanism may be implemented in connection with either terminal of puncture sensor210(and/or conductive path222). In some embodiments, even a momentary fault condition may be detected by BMS502(e.g., on the order of milliseconds or microseconds). In some embodiments, flip-flop circuit1016may be configured to detect a small change in a value of an electrical characteristic, even if such change persists for only a short period of time, which may be an indication of a deformation event, e.g., flip-flop circuit1016may be configured to hold such value.

In some embodiments, a variable resistor may be employed to detect changing resistance values in connection with puncture sensor210(and/or conductive path222), in determining whether a deformation event has or is occurring. In some embodiments, such as in the example described in connection withFIG.8, a deformation event may be determined based on detecting a closed circuit condition, e.g., based on signals output by comparator1014and flip-flop circuit1016indicative of a closed circuit configuration. In some embodiments, a deformation event corresponding to a puncture of battery pack100may correspond to a reading by BMS502of, e.g., 5 V, corresponding to a supply voltage of a battery included in circuitry1000. On the other hand, the deformation event may correspond to a bend or deformation of battery pack100but may not rise to level of a puncture. BMS502may determine the occurrence of such an event based on a relatively minor voltage change measured, e.g., at1018, in a closed circuit condition, as opposed to the open circuit condition of detecting, e.g., 5 V. In some embodiments, flip-flop1016may not be triggered in the event of a deformation event that does not rise to the level of a puncture.

FIG.11shows a flowchart of illustrative process1100for determining the occurrence of a deformation event based on monitoring electrical characteristics of a puncture sensor, in accordance with some embodiments of the present disclosure. Process1100may be executed at least in part by processing circuitry902.

At1102, processing circuitry902may monitor one or more electrical characteristics (e.g., resistance, voltage, current) of puncture sensor210(and/or conductive path222) of battery pack100. For example, processing circuitry902may be configured to execute instructions stored in memory905to implement battery management system502. Battery management system502may comprise, or otherwise be configured to be in communication with, circuitry1000shown inFIG.10which may be coupled to puncture sensor210(and/or conductive path222).

At1104, processing circuitry902may detect whether a change in an electrical characteristic of puncture sensor210(and/or conductive path222) has occurred. For example, BMS502may receive input at1018ofFIG.10and/or may receive input at1020ofFIG.10. The input may be based on a signal received by way of electrical connectors215,217, and may be detected based on a transition of conductive path222and/or puncture sensor210from a first circuit state to a second circuit state. For example, such one or more inputs may indicate the presence of resistance change associated with puncture sensor210(and/or conductive path222), an open circuit condition of puncture sensor210and/or conductive path222(e.g., corresponding to a voltage reading of 5 V), and/or an output of flip-flop circuit1016may be indicative of at a momentary transition of puncture sensor210(and/or conductive path222) from a closed circuit state to an open circuit state (or vice versa, from an open circuit state to a closed circuit state).

At1106, processing circuitry902may determine whether the changed characteristic (e.g., a resistance value of puncture sensor210, and/or conductive path222, determined based on a changed voltage reading) is associated with a puncture to bottom layer106of battery pack100. For example, processing circuitry902may compare the electrical characteristic to a first predetermined threshold, to determine whether the measured value corresponds to (e.g., is within a predefined range of) a particular state of puncture sensor210and/or conductive path222(e.g., an open circuit condition of 5 V). If processing circuitry902determines the electrical characteristic does correspond to the value indicative of a puncture of battery pack100, processing may proceed to1110. If processing circuitry902determines the electrical characteristic does not correspond to the value indicative of a puncture of battery pack100, processing may proceed to1108.

At1108, processing circuitry902may determine whether the changed characteristic (e.g., a resistance value of puncture sensor210and/or conductive path222determined based on a changed voltage reading) is associated with a bend or deformation to bottom layer106of battery pack100, even if the electrical characteristic value is not indicative of a puncture to battery pack100. For example, processing circuitry902may detect that a voltage associated with puncture sensor210and/or conductive path222corresponds to a value (e.g., 4.0 V) that does not indicate an open circuit condition of puncture sensor210and/or conductive path222, but nonetheless indicates some significant change in puncture sensor210and/or conductive path222, based on such value corresponding to a second predetermined value indicative of a deformation or bend. In response to this detection, processing may proceed to1112. Otherwise, processing may continue to1102to continue monitoring the one or more electric characteristics of puncture sensor210and/or conductive path222.

At1110, processing circuitry902may determine, based on a determination at1106that a value of the electric characteristic of puncture sensor210and/or conductive path222is indicative of a puncture, that battery pack100(e.g., bottom layer106thereof, or another portion of battery pack100) is punctured. On the other hand, at1112, processing circuitry902may determine, based on a determination at1108that a value of the electric characteristic of puncture sensor210and/or conductive path222is indicative of a bend or other deformation (e.g., other than a puncture), that battery pack100(e.g., bottom layer106thereof, or another portion of battery pack100) is bent or deformed. In some embodiments, processing circuitry902determining a deformation event may correspond to the determination at1110and/or1112.

At1114, processing circuitry902may generate for output a notification indicative of the determination at1112that bottom layer106of battery pack100(or another portion thereof) is deformed or bent. For example, the notification may be generated for display at display912of electric vehicle901and/or a display of user device918. In some embodiments, the notification may additionally or alternatively comprise an audio alert by way of speaker914and/or a tactile alert. In some embodiments, communications circuitry906may communicate with a service scheduling system920(e.g., a server or human technician or operator associated with a manufacturer of electric vehicle901) to schedule repair or maintenance of vehicle901regarding the determined bend or deformation of battery pack100.

At1116, processing circuitry902may determine, based on sensor data provided by isolation loss sensor916, whether the sensor data is indicative of the occurrence of isolation leakage. Isolation loss sensor916may monitor isolation resistance as between high-voltage components of vehicle901and chassis ground. For example, if a deformation event is detected, and subsequently isolation loss is detected by isolation loss sensor916, processing circuitry902may cause a notification to be generated for output (e.g., at vehicle display912and/or vehicle speaker914and/or at user device918). For example, isolation loss may be detected based on a detected leakage current exceeding a threshold. In some embodiments, processing circuitry902may determine whether the isolation loss is detected within a threshold period of time after the detection of a deformation event being detected. If so, processing circuitry902may infer that the object causing the deformation event may have made contact with a bus bar of battery pack100.

At1118, processing circuitry902may determine, based on the sensor data provided by isolation loss sensor916, that isolation loss is not present and may generate for output a notification indicative of the determination at1110that bottom layer106of battery pack100(or another portion thereof) is punctured. For example, the notification may be generated for display at display912of electric vehicle901and/or a display of user device918. In some embodiments, the notification may additionally or alternatively comprise an audio alert by way of speaker914and/or a tactile alert. In some embodiments, communications circuitry906may communicate with a service scheduling system920(e.g., a server or human operator associated with a manufacturer of electric vehicle901) to schedule repair or maintenance of vehicle901regarding the determined puncture of battery pack100.

At1120, processing circuitry902may determine, based on the sensor data provided by isolation loss sensor916, that isolation loss is present and may generate for output one or more notifications indicative of the determination at1110that bottom layer106of battery pack100(or another portion thereof) is punctured, and indicative of the determination related to the occurrence of the isolation loss. For example, the one or more notifications may be generated for display at display912of electric vehicle901and/or a display of user device918. In some embodiments, the notification may additionally or alternatively comprise an audio alert by way of speaker914and/or a tactile alert. In some embodiments, communications circuitry906may communicate with a service scheduling system920(e.g., a server or human operator associated with a manufacturer of electric vehicle901) to schedule repair or maintenance of vehicle901regarding the determined puncture of battery pack100and the determined isolation loss.

In some embodiments, processing circuitry902may perform the determination at1116, and/or any other suitable determinations with respect to received sensor signals (e.g., a determination associated with an output of water sensor922), in parallel or in conjunction with the determinations at1106,1108,1110and1112. In some embodiments, processing circuitry902may determine or generate a confidence score based on one or more of such sensor outputs, such that the confidence score impacts a type of alert or notification that is to be output, and/or the content of such alert or notification. For example, if processing circuitry902determines that water is present in battery pack100, and detects a changed electrical characteristic of conductive path222, a notification to be output may indicate or otherwise be based on each of these determinations. If processing circuitry902determines that isolation leakage is present in battery pack100, and detects a changed electrical characteristic of conductive path222, a notification to be output may indicate or otherwise be based on each of these determinations. In some embodiments, a confidence score may depend on an amount by which the electrical characteristic of conductive path222changed or an amount by which the electrical characteristic exceeds a threshold, and/or based on an amount of time for which the electrical characteristic exceeds the threshold, and/or the magnitude of an isolation leakage measurement and/or a water sensor measurement and an amount of time that such measurements persisted.

It should be appreciated that process1100is merely illustrative and various modifications can be made within the scope of the disclosure. For example, one or more steps (e.g., steps1108,1112,1114,1116and1120) can be optional. In some embodiments, when a puncture is determined at1110, process1100may proceed to1118to generate for output a notification of the puncture. Additionally or alternatively, a leakage determination may be made at1116after a determination at1112is made by processing circuitry902. In some embodiments, if multiple puncture sensors210and/or conductive paths222are utilized (e.g., as in the example ofFIGS.6-7) such that processing circuitry902may determine a precise location of a deformation event, process1100may include a step of monitoring each of the respective puncture sensors210and/or conductive paths222and providing notifications (e.g., to the operator of vehicle901and/or user device918and/or to service scheduling system920) to indicate the determined location of the deformation event.