Custom printed sensor increases battery safety and performance: A FLEXOO case study

A leading North American provider of scalable energy storage systems sought to enhance the precision of its battery monitoring. The goal was to deliver more precise battery monitoring for their existing product lines.

The challenges: Maximizing battery capacity while maintaining integrity

FLEXOO was engaged to overcome several key obstacles faced by the customer:

Precise monitoring needs: The existing thermistor temperature data needed to be complemented with high-resolution measurements taken in real-time, directly at the cell level.
Real-time data utilization: The solution needed to provide real operational data that would allow maximum utilization of the temperature limits specified by the cell manufacturer. This utilization had to increase usable cell capacity without changing cell size or pack costs, all while ensuring warranty claims remained intact.
Data management & connectivity: The solution required robust data management and battery monitoring system connectivity for reliable communication.
Scalability & Integration: The final system needed to be a scalable and adaptable solution that could integrate seamlessly into existing product lines.
Physical integration: A key requirement was the physical integration of on-cell sensors into the existing battery pack design.

FLEXOO’s approach: Precision meets scalability

FLEXOO engineered a customized printed sensor solution designed for both high precision and easy integration into automated production processes.

1. Concept, design, and tailored integration

FLEXOO created a sensor matrix capable of simultaneously measuring cell-level pressure and temperature. This matrix transmits real-time data to the battery management system via defined interfaces.

Achieving seamless physical integration was critical:

Precise positioning: The exact positioning of sensors, connectors, and FFC cables was engineered to align with cell geometry and automated production processes. Sensors are positioned on the film to match the cell-to-cell spacing, and the number of sensors corresponds to the pack width. The length of the sensor flaps is designed to match the pack depth, which ensures proper positioning of the measurement points.
BMS integration: The connector position and layout were designed to align with the battery management system, ensuring proper interface compatibility.

2. Prototype and production

Prototypes were manufactured for functional testing. The final sensor matrix was engineered for series production using high-volume roll-to-roll printing processes. Substrate and ink selection were designed for a long service life, ensuring consistent performance throughout the operational period and providing reliable real-time data.

3. The most precise printed sensor

For the pressure measurement, FLEXOO selected its Prime Mode Sensor. This printed sensor is currently the most precise worldwide, making it the right choice for high demands on accuracy and response time for enhanced safety. The custom in-situ cell sensors maximize battery capacity without compromising the pack design. Furthermore, the sensors are calibrated to the precompression in the battery pack, ensuring optimal performance under real operating conditions.

Benefits delivered

The resulting custom sensor system delivered significant benefits to the customer:

Increased energy yield: Higher energy output was achieved without investing in battery pack design changes or losing manufacturer warranties.
Enhanced safety: Safety reached a higher, more controllable level through real-time cell-level monitoring of both temperature and pressure.
Cost efficiency: The solution maximizes battery utilization without increasing cell size or pack costs, improving overall Return on Investment (ROI).

Key outcomes: Enhanced safety and maximized capacity

Increased energy yield and capacity:

Outcome: The solution delivered a higher energy output without requiring investment in battery pack design changes or losing manufacturer warranties.
Mechanism: Real operational data allows for the maximum utilization of temperature limits specified by the cell manufacturer, increasing usable cell capacity without changing cell size or pack costs.

Enhanced safety and precision:

Outcome: Safety reached a higher, more controllable level through real-time cell-level monitoring of both temperature and pressure.
Mechanism: The solution provided high-resolution measurements taken in real-time directly at the cell level, utilizing the Prime Mode Sensor, which is currently the most precise printed sensor worldwide.

Cost efficiency and integration:

Outcome: Maximized battery utilization without increasing cell size or pack costs, thereby improving overall Return on Investment (ROI).
Mechanism: The sensor matrix was engineered for series production using high-volume roll-to-roll printing processes, providing a scalable and adaptable solution that integrates into existing product lines.

Conclusion: Achieving peak performance and ROI

FLEXOO successfully delivered a high-precision, scalable solution that achieved the customer's core goal of maximizing battery utilization without compromising safety. By providing real-time, cell-level data via the world's most precise printed sensor (Prime Mode Sensor), the customer gained a higher, more controllable level of safety. The seamless integration into existing product lines, achieved through precise engineering and roll-to-roll manufacturing, directly translated into increased energy yield and cost efficiency, confirming the system's ability to boost overall return on investment (ROI) without expensive pack redesigns or jeopardizing manufacturer warranties.

FLEXOO: The innovator in printed electronics

FLEXOO specializes in cutting-edge printed electronics. We serve our clients through comprehensive services, including contract engineering and contract manufacturing. Our broad spectrum of solutions leverages the latest advancements in printed technology to deliver innovative components, such as: