This temperature monitoring tech to prevent fire, make lithium batteries safer for EVs

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This temperature monitoring tech to prevent fire, make lithium batteries safer for EVs


TTape helps detect hotspots vulnerable to thermal runaway on lithium-ion batteries to prevent fire, and explosions and also extend the lifespan of the batteries.Updated: Aug 17, 2024 03:28 PM EST





Littelfuse crafts tech to prevent fires, explosions rendered by overheating in lithium-ion batteries in EVs. (Representational image)

Despite most electric vehicle (EV) manufacturers resorting to lithium batteries, these betters can suffer through thermal runaway if damaged under very high loads, overcharged, or exposed to high temperatures. Such a situation can lead to fire or an explosion of a battery pack, putting EV passengers at risk.

Therefore, Littelfuse an American electronics manufacturing company based in Chicago developed a new technology platform, TTape Distributed Temperature Monitoring Device to enable early detection of localized battery cell overheating.

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The platform has been devised to improve the performance and lifespan of EV batteries by providing advanced temperature monitoring.
Mitigating risks of battery thermal runaway

Aiming to mitigate the risks of battery thermal runaway, TTape presents a creative temperature monitoring solution for lithium-ion batteries used in EVs.

TTape is a thin, flexible strip of tape embedded with closely spaced temperature indicators that detect localized overheating in battery cells.

The flexible design allows it to conform to the irregular shapes of battery packs, making it suitable for various battery configurations used in the automotive industry.

In contrast to a thermistor, TTape conforms to battery cells and the shape of the cells, allowing high-density monitoring of locations on a battery pack.

EV Engineering News stated that the temperature-indicating sensors quickly detect a cell hot spot preventing battery thermal runaway. With individual thermistors whose size limits the number of detection locations and prevents close spacing, a battery cell hot spot that is not near the location of a thermistor could rise to a dangerous level.



“TTape solves the problem of being unable to detect battery cell hot spots quickly.”

PTIs embedded on thin tape

The technology platform functions by deploying printed temperature indicators (PTIs) embedded in a thin tape. They are spaced closely together and connected in series.

When a PTI detects a temperature above a specified threshold (58 ± 3 degrees Celsius), its resistance increases sharply, signaling the potential for overheating. The TTape is connected to an electronic circuit that can trigger a response, such as cutting off power, to prevent further heating.

The high spatial resolution of TTape allows it to monitor temperature changes across the entire battery pack, providing early warning of potential hot spots before they can cause damage.

This system is easy to integrate into existing battery management systems (BMS) along with traditional NTC sensors and consumes minimal power, making it an efficient and effective solution for enhancing EV battery safety.


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“The TTape platform is a distributed temperature monitoring technology for battery packs that helps to improve the detection of localized cell overheating,” Littelfuse stated.

“This helps to increase the lifetime of batteries and provides thermal runaway protection.”

The device is easy to use as it doesn’t require calibration or temperature conversion tables. The tape uses a pressure-sensitive adhesive for quick and straightforward installation.

Additionally, it’s AEC-Q200 qualified, meaning it’s tested and approved for automotive use, ensuring reliability and safety in vehicles.

Overall, the developers at Littelfuse strove to craft a platform that enhanced the performance of EV batteries and expanded their lifespans by preventing major hazardous spots.


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