Cubic Innovative Thermal Runaway Sensor Solutions

In the production and application of lithium batteries, thermal runaway is a critical safety concern. Thermal runaway is a phenomenon in which the internal temperature of a lithium battery rises sharply due to overcharging, over-discharging, short circuits, or external high temperatures, triggering a chain reaction, leading to fires or even explosions, potentially causing severe accidents. During thermal runaway, the battery releases multiple gases, including carbon dioxide (CO2), hydrogen (H2) and carbon monoxide (CO), which could serve as indicators of thermal runaway for early warning.

Among the gases emitted during thermal runaway, carbon dioxide (CO2) has emerged as the most critical and reliable early indicator. CO2 is consistently generated in substantial quantities at the initial stage of thermal runaway, making it indispensable for early warning systems. The effective detection of CO2 concentration based on NDIR technology provides a stable and prompt signal to indicate the onset of thermal events, enabling timely and proper intervention to prevent escalation to severe events.

At the same time, hydrogen (H2) and carbon monoxide (CO) are also regarded as effective indicator gas to provide early warnings for thermal runaway events. However, in practical applications, it indicates that the single H2 detection based on thermal conductivity or single CO detection based on MOX technology are not reliable as CO2 detection. H2 may be released when the battery is aged, leaking slightly, or slightly overheating, rather than thermal runaway, which can easily lead to false alarms. CO is easier to release under non-thermal runaway conditions than H2 and it lacks sufficient trigger signal reliability and is not stable and indicative. The detection of these two gases cannot clearly determine whether thermal runaway has actually occurred. Carbon dioxide is a core gas released in large quantities during the violent decomposition of electrolytes and electrode materials, and is one of the key features of the thermal runaway process. Therefore, CO2 should be the basis of H2 or CO in order to effectively distinguish between minor abnormalities and thermal runaway and build a more accurate and timely battery safety early warning system.

To provide more reliable thermal runaway detection, Cubic, as a leading manufacturer of gas sensors and gas analyzers, innovatively combines non-dispersive infrared (NDIR), thermal conductivity (TC) technology and MEMS MOX technology to integrate comprehensive sensor solutions to effectively monitor CO2, H2 and CO released from lithium-ion batteries, and generate an early warning signal to Battery Management System (BMS), to formulate safety alarm strategies.

The integrated thermal runaway sensor solutions have remarkable characteristics of fast response time, reliable measurement, no false alarm, long life time and low power consumption, could be widely used for Li-battery electrical vehicle and energy storge system. It also demonstrates significant advantages in helping detect potential thermal runaway risks earlier and more accurately, enabling effective preventive measures to avoid accidents in advance.

Furthermore, Cubic thermal runaway sensor solutions also represent the forefront of gas detection technology in the field of thermal runaway events and underscore Cubic’s capability to enhancing safety. With long-term dedication in R&D, Cubic will continuously improve the reliability of gas sensors to meet the dynamic demands, fostering safer environments and empowering the battery-related industry.

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