THermally Insensitive Pressure Sensor with High Sensitivity and Broad Detection Range for Status Monitoring of Battery Module

Reliable real-time monitoring of lithium-ion battery (LIB) status is critical for ensuring both safety and performance, particularly in densely packed module designs. However, conventional voltage- and temperature-based diagnostics often lack the sensitivity required for early-stage fault detection. Here, we present a temperature-insensitive, flexible resistive pressure sensor designed for real-time LIB monitoring. The sensor comprises carbon nanotube-based sensing layers and silver nanowire-based electrodes, offering high sensitivity, wide detection range, and low temperature coefficient of resistance. These features are enabled by the rough surface morphology of the sensing layer and the optimized temperature dependence of its resistance. Integrated into a pouch-cell module, the sensor reliably captured pressure variations during charge and discharge cycles, demonstrating its potential as a compact and sensitive platform for precise diagnostics and early fault detection in LIB systems.