Cubic Pressure Sensor Empowers Electric Vehicle Thermal Runaway Monitoring

Real-Time Pressure Monitoring Providing Early Warning for Safer Li-battery Systems and Smarter Thermal Management

The global electric vehicle market continues to grow rapidly. In electric vehicles, Li-battery systems have become a core part because of the direct impact on vehicle safety and performance. As battery energy density continues to increase, battery system safety has become a major focus for automakers and end users, especially due to thermal runaway concerns. Thermal runaway is a serious safety risk in Li-battery applications. It may be triggered by internal short circuits, overcharging, overheating, or mechanical damage. Once the failure process starts, the battery cell may release heat within a short time. The battery pack may then face pressure build-up, venting, fire, or even explosion. Early detection is therefore critical for improving vehicle safety.

Pressure change is an important signal during battery thermal runaway. When abnormal thermal condition occurs inside the battery cell, pressure inside the battery pack or designated monitoring space may change rapidly. Research has also shown that mechanical signals, including pressure, can be more suitable than temperature as early safety indicators in certain thermal runaway scenarios. Therefore, real-time pressure monitoring can help identify abnormal battery conditions at an earlier stage. The pressure signal can provide useful input for the Battery Management System, enabling the BMS to support safer warning strategies.

In response to the market demand, Cubic, as an automotive Tier 1 supplier, has developed the ATRS-1015 series pressure sensor based on MEMS technology for the monitoring of pressure variations during Li-battery thermal runaway events, providing early warning signal to support safety alarm strategies. Equipped with a self-developed pressure chip, the ATRS-1015 series features stable performance, fast response, and wide measurement range, enabling rapid detection of pressure change near the battery pack pressure relief valve. Built with automotive-grade components, Cubic ATRS-1015 pressure sensor is designed in accordance with AEC-Q100 automotive electronics requirements and supports EMC compliance for a wide range of vehicle platforms, helping customers simplify system integration. In addition, the pressure sensor features ultra-low power consumption, with sleep-mode quiescent current reaching the μA level, reducing system power consumption during long-term onboard monitoring. Furthermore, the pressure sensor transmits real-time measurement data to the Battery Management System (BMS) via CAN communication, enabling safer early warning strategies for electric vehicles. Other than the core features, the sensor lifespan could reach 15 years, making it an ideal monitoring solution for thermal runaway.

Beyond pressure sensor, battery thermal runaway involves multiple physical and chemical changes that can provide other valuable early-warning signals. To support more comprehensive monitoring, Cubic offers a broader sensing portfolio covering CO₂, CO, H₂, aerosol, and electrolyte vapor detection. Based on multiple signals sensing capability, different indicators generated during different stages of thermal runaway can be detected, providing the battery management system with more comprehensive information to support early warning and safety strategies.

Building on extensive experience in the independent development and production of core automotive-grade components, Cubic has established strong software development capabilities aligned with ASPICE standards. Furthermore, an IATF 16949-certified quality management system helps ensure that Cubic comprehensive thermal runaway solutions meet stringent automotive quality requirements. The thermal runaway solutions have been adopted across a wide range of global OEM programs, demonstrating reliable performance through long-term field operation.