Increasing Battery Safety and Performance

Precise monitoring needs

More precise battery monitoring – that was the goal of a leading North American provider of scalable energy storage systems. The solution needed to complement existing thermistor temperature data with high-resolution measurements taken in real-time directly at cell level.

Real-time data

This real operational data allows maximum utilization of the temperature limits specified by the cell manufacturer. Warranty claims remain intact while increasing usable cell capacity without changing cell size or pack costs.

Physical integration

Physical integration of on-cell sensors into existing battery pack design.

Data management

Robust data management and BMS connectivity for reliable communication.

Scalability

Scalable and adaptable solution that integrates into existing product lines.

Concept & Design

• Created a sensor matrix that simultaneously measures cell-level pressure and temperature, transmitting real-time data to the BMS via defined interfaces.

Tailored integration

• Engineered exact positioning of sensors, connectors, and FFC cables for integration into automated battery pack production.

Prototype & Production

• Manufactured prototypes for functional testing and engineered the sensor matrix for series production using high-volume roll-to-roll printing processes.

Precise positioning

• Sensor positioning on the film matching cell-to-cell spacing​
• Number of temperature and pressure sensors matching pack width​
• Length of sensor flaps matching pack depth for optimal measurement point positioning​

BMS integration

• Connector position and layout matching BMS connection grid spacing

Reliable real-time data

• Substrate and ink selection designed for long service life

Consultation

Schedule a free consultation with our experts and learn how printed electronics can optimize your BESS.

Project launch

Ready to optimize your BESS? Contact our specialists today and discover how we can increase safety and energy output without changing the battery pack design.

Most precise printed sensor

For pressure measurement, FLEXOO's Prime Mode Sensor was selected. 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.

Increased energy yield

• Higher energy output without investing in battery pack design changes or losing manufacturer warranties.

Enhanced safety

• Safety reaches a higher, more controllable level through real-time cell-level monitoring of both temperature and pressure.

Cost efficiency

• Maximizes battery utilization without increasing cell size or pack costs, improving overall ROI.