This paper proposes to apply a newly developed Non-Dispersive Infrared Spectroscopy (NDIR) gas sensing system composed of pyroelectric infrared detectors to monitor the thermal runaway (TR) process of lithium-ion batteries in real time and achieve an early warning system for the battery TR process. The new Electrical Vehicle Safety—Global Technical Regulation (EVS-GTR) requires that a warning be provided to passengers at least five minutes before a serious incident. The experimental results indicate that carbon dioxide and methane gas were detected during the overcharge test of the automotive battery, and the target gas was detected 25 s in advance before the battery TR when the battery vent was closed. In order to further explore the battery TR mechanism, an experiment was carried out using the battery sample with the battery vent opened. The target gas was detected about 580 s before the battery temperature reached the common alarm temperature (60 °C) of the battery management system (BMS). In this study, the beneficial effects of NDIR gas sensors in the field of thermal runaway warnings for automotive batteries were demonstrated and showed great application prospects and commercial value.

Increasing concerns about air quality due to fossil fuel combustion, especially nitrogen oxides (NO_x) from marine and diesel engines, necessitate advanced monitoring systems due to the significant health and environmental impacts of nitrogen dioxide (NO₂). In this study, a gas detection system based on the principle of the non-dispersive infrared (NDIR) technique is proposed. Firstly, the pyroelectric detector was developed by employing an ultra-thin LiTaO₃ (LT) layer as the sensitive element, integrated with nanoscale carbon material prepared by wafer-level graphics technology as the infrared absorption layer. Then, the sensor was hermetically sealed using inert gas through energy storage welding technology, exhibiting a high detectivity (D*) value of 4.19 × 10⁸ cm·√Hz/W. Subsequently, a NO₂ gas sensor was engineered based on the NDIR principle employing a Micro Electro Mechanical System (MEMS) infrared (IR) emitter, featuring a light path chamber length of 1.5 m, along with integrated signal processing and software calibration algorithms. This gas sensor was capable of detecting NO₂ concentrations within the range of 0–500 ppm. Initial tests indicated that the gas sensor exhibited a full-scale relative error of less than 0.46%, a limit of 2.8 ppm, a linearity of −1.09%, a repeatability of 0.47% at a concentration of 500 ppm, and a stability of 2% at a concentration of 500 ppm. The developed gas sensor demonstrated significant potential for application in areas such as industrial monitoring and analytical instrumentation.