Development of a Polymer-Encapsulated IoT-Based Sensor for Thermal and Electrical Protection of EV Batteries

Year : 2025 | Volume : 13 | Special Issue 06 | Page : 582 591
    By

    Chandrmani Yadav,

  • Bhagwat Kakde,

  • Mukesh Tiwari,

  • Ankur Saxena,

  1. Assistant Professor, Department of Mechanical Engineering, Marwadi University Research Center, Faculty of Engineering & Technology, Marwadi University, Rajkot, Gujarat, India
  2. Associate Professor, Department of Electronics & Telecommunication Engineering, Sandip Institute of Technology and Research Centre, Nashik, Maharashtra, India
  3. Assistant Professor, Department of Electronics & Telecommunication Engineering, Padmabhooshan Vasantdada Patil Institute of Technology, Bavdhan, Pune, Maharshtra, India
  4. Assistant Professor, Department of Electronics and Communication Engineering, Bharat Institute of Engineering and Technology, Hyderabad, Telangana, India

Abstract

Electric Vehicles (EVs) mark a critical shift toward sustainable transportation, with Battery Management Systems (BMS) playing a vital role in ensuring battery safety, reliability, and efficiency. The proposed BMS in this project incorporates real-time charge monitoring, temperature sensing, and fire detection capabilities to address safety concerns associated with lithium-ion batteries. Key features include current and voltage tracking, State of Charge (SoC) estimation, fault detection, and a user-friendly LCD interface. By continuously evaluating battery parameters, the system prevents overcharging, overheating, and thermal runaway, helping avoid fire hazards while extending battery life. A significant innovation in this design is the integration of polymer and polymer composite materials in key components. Flame-retardant polymer enclosures are used to insulate high-voltage circuits and protect electronics from thermal damage. Phase change materials (PCMs) and thermally conductive polymer composites support effective heat dissipation around battery modules and Peltier cooling elements. These materials are lightweight, electrically insulating, and capable of withstanding high temperatures ideal for electric vehicle environments. The use of polymer-based solutions strengthens the system’s ability to prevent and contain fire incidents, contributing to a safer EV ecosystem. By combining intelligent electronics with materials engineering, the proposed BMS not only improves safety and performance but also promotes broader acceptance of EV technology through enhanced user trust and operational resilience.

Keywords: Electric Vehicle, Battery Management System, Fire Protection, Polymer.

[This article belongs to Special Issue under section in Journal of Polymer and Composites (jopc)]

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How to cite this article:
Chandrmani Yadav, Bhagwat Kakde, Mukesh Tiwari, Ankur Saxena. Development of a Polymer-Encapsulated IoT-Based Sensor for Thermal and Electrical Protection of EV Batteries. Journal of Polymer and Composites. 2025; 13(06):582-591.
How to cite this URL:
Chandrmani Yadav, Bhagwat Kakde, Mukesh Tiwari, Ankur Saxena. Development of a Polymer-Encapsulated IoT-Based Sensor for Thermal and Electrical Protection of EV Batteries. Journal of Polymer and Composites. 2025; 13(06):582-591. Available from: https://journals.stmjournals.com/jopc/article=2025/view=227326


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Special Issue Subscription Original Research
Volume 13
Special Issue 06
Received 10/06/2025
Accepted 18/07/2025
Published 17/09/2025
Publication Time 99 Days
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