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Enhancing Lithium-ion Battery Safety with a Multilayer Integrated Sensor for Synchronous Thermal-Mechanical

Shangsong Li¹, Qinlang Rong¹, Nuo Sun¹

¹School of Chemical Engineering, Sichuan University, Chengdu, China.

Advanced Materials (Deerfield Beach, Fla.)

|March 28, 2026

Summary

A new multilayer temperature-pressure sensor (MTPS) enables simultaneous, precise monitoring of thermal and mechanical signals in lithium-ion batteries. This technology enhances state estimation and early fault detection for improved battery safety.

Keywords:

battery safety flexible integrated sensors real‐time temperature and pressure sensing thermal‐mechanical monitoring

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Area of Science:

Materials Science
Electrochemical Engineering
Sensor Technology

Background:

Accurate state estimation and fault diagnosis in lithium-ion batteries require real-time, colocated thermal and mechanical signal monitoring.
Existing methods face challenges with spatial asynchrony and signal crosstalk, limiting diagnostic accuracy.

Purpose of the Study:

To develop a compact, flexible multilayer temperature-pressure sensor (MTPS) for synchronous, colocated, high-fidelity dual-parameter monitoring on battery cell surfaces.
To overcome limitations of existing sensor strategies in spatial asynchrony and inter-signal crosstalk.

Main Methods:

Designed a vertically co-laminated architecture integrating temperature and pressure sensing units.
Implemented a hardware-based compensation model to decouple thermal-mechanical interference.
Utilized operando deployment for monitoring battery failure modes and system-level diagnostics.

Main Results:

The MTPS achieved high-sensitivity temperature sensing (TCR of -0.6% °C^-1) and wide-range pressure sensing (0-1000 kPa).
Demonstrated accurate tracking of failure signatures like lithium plating, side reactions, and mechanical damage.
Successfully distinguished cell inconsistencies in battery packs and detected underbody scraping in a vehicle.

Conclusions:

The MTPS provides a practical platform for real-time, precise, and intelligent battery safety monitoring.
Enables early fault warning and elucidation of failure mechanisms through non-intrusive dual-parameter sensing.
Offers a pathway for enhanced safety management in various lithium-ion battery applications.