Advanced Thermal Runaway Sensing

What the client needed

The client sought a comprehensive technical evaluation of lithium-ion battery failure mechanisms to refine their system-level safety strategies. Specifically, they required an expert assessment of early detection methodologies—including gas sensing, pressure monitoring, and ultrasonic techniques—to identify the onset of thermal runaway before catastrophic propagation. The project focused on quantifying the performance trade-offs of various sensor technologies regarding response time, signal reliability, and integration feasibility for high-volume manufacturing.

Choosing PB Consulting

With specialised expertise in battery safety and a background in rigorous industrial research, PB Consulting provided a data-driven framework for understanding complex failure modes like internal short circuits and electrolyte venting. This deep technical proficiency enabled the translation of complex electrochemical behaviours into actionable engineering requirements for enhanced module and pack-level protection.

Outcomes

The engagement delivered a structured roadmap for the implementation of advanced early-warning systems and mitigation measures, such as optimised thermal barriers and venting designs. By benchmarking sensor performance against diverse failure triggers, the client gained the necessary technical validation to drive innovation in safety-critical battery management systems, ultimately reducing the risks of thermal incidents in next-generation applications.