Battery system comprising battery cell and hydrogen permeable membrane

Abstract

A battery system including a battery cell and a hydrogen permeable membrane is provided. In one example, a battery system includes a battery cell. The battery cell includes a battery cell housing disposed around an interior of the battery cell. At least one multilayer stack is disposed inside the cell and includes a cathode, an anode, and a separator disposed therebetween. The hydrogen permeable membrane is in fluid communication with the cell interior and is configured to selectively allow any hydrogen gas generated in the cell to pass through the hydrogen permeable membrane from the cell interior to the cell exterior while substantially preventing other fluids from passing through the hydrogen permeable membrane.

Description

Technical Field

[0001] The present disclosure relates generally to battery systems, and more particularly, to battery systems including a battery cell and a hydrogen permeable membrane in fluid communication with the battery cell. Background Art

[0002] Battery systems play a vital role in storing and supplying electrical energy (i.e., electricity) for many applications. Examples of applications using battery systems include electric vehicles, consumer products (e.g., laptops, tablets, mobile phones), and energy storage systems (i.e., systems that provide grid power to homes, hospitals, data centers, entire cities, or general electricity).

[0003] The battery system includes battery cells, which are responsible for storing and supplying electrical energy. A battery cell (ie, electrochemical cell) is a device that generates electrical energy through a chemical reaction. Summary of the invention

[0004] A battery system is provided. The battery system includes a first battery cell. The first battery cell includes a first battery cell housing disposed around the interior of the first battery cell and at least one first multilayer stack disposed inside the first battery cell and including a first cathode, a first anode, and a first separator disposed between the first anode and the first cathode. The battery system also includes a first hydrogen permeable membrane in fluid communication with the interior of the first battery cell. The first hydrogen permeable membrane is configured to selectively allow any hydrogen generated in the first battery cell to pass through the first hydrogen permeable membrane from the interior of the first battery cell to the outside of the first battery cell, while substantially preventing other fluids from passing through the first hydrogen permeable membrane.

[0005] In some embodiments, the battery system further includes a first hydrogen sensor in fluid communication with the first hydrogen permeable membrane. The first hydrogen sensor is configured to detect the presence of hydrogen that has passed through the first hydrogen permeable membrane and is proximate to the first hydrogen sensor.

[0006] In some embodiments, the first hydrogen sensor is configured to detect the presence of hydrogen in an amount of about 1 ppm to about 1000 ppm or greater.

[0007] In some embodiments, the battery system also includes a first battery module. The first battery module includes a first plurality of battery cells, wherein the first plurality of battery cells include a first battery cell and a second battery cell. The second battery cell includes a second battery cell housing, the second battery cell housing is defined and disposed around the interior of the second battery cell, and at least one second multilayer stack. The second multilayer stack is disposed inside the second battery cell and includes a second cathode, a second anode, and a second diaphragm disposed between the second anode and the second cathode. The battery system also includes a second hydrogen permeable membrane in fluid communication with the interior of the second battery cell. The second hydrogen permeable membrane is configured to selectively allow any hydrogen generated in the second battery cell to reach the outside of the second battery cell from the inside of the second battery cell through the second hydrogen permeable membrane, while substantially preventing other fluids from passing through the second hydrogen permeable membrane.

[0008] In some embodiments, the first hydrogen sensor is in fluid communication with the second hydrogen permeable membrane and is configured to detect the presence of hydrogen that has passed through the second hydrogen permeable membrane. The second hydrogen permeable membrane is adjacent to the first hydrogen sensor.

[0009] In some embodiments, the battery system further comprises a cell management device in communication with the first hydrogen sensor and operable to determine a hydrogen concentration and / or a rate of change of the hydrogen concentration with respect to time in response to detecting the presence of hydrogen by the first hydrogen sensor. The cell management device is operable to compare the concentration and / or the rate of change with a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold.

[0010] In some embodiments, the battery cell management device is operable to direct a control action in response to the concentration and / or rate of change exceeding a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold. The control action includes sending a warning notification to a receiving device.

[0011] In some embodiments, the receiving device includes a battery management system.

[0012] In some embodiments, the battery system further comprises a battery pack. The battery pack comprises a plurality of battery modules, the plurality of battery modules comprising a first battery module and a second battery module. The second battery module comprises a second plurality of battery cells, a third battery cell and a fourth battery cell. The third battery cell comprises a third battery cell housing defining the interior of the third battery cell and arranged around the interior of the third battery cell, and at least one third multilayer stack. The third multilayer stack is disposed inside the third battery cell and comprises a third cathode, a third anode and a third diaphragm disposed between the third anode and the third cathode. The battery system further comprises a third hydrogen permeable membrane in fluid communication with the interior of the third battery cell. The third hydrogen permeable membrane is configured to selectively allow any hydrogen produced in the third battery cell to pass through the third hydrogen permeable membrane from the interior of the third battery cell to the outside of the third battery cell, while substantially preventing other fluids from passing through the third hydrogen permeable membrane. The fourth battery cell comprises a fourth battery cell housing and at least one fourth multilayer stack, the fourth battery cell housing defining the interior of the fourth battery cell and arranged around the interior of the fourth battery cell. The fourth multilayer stack is disposed inside the fourth battery cell and comprises a fourth cathode, a fourth anode and a fourth diaphragm disposed between the fourth anode and the fourth cathode. The battery system further comprises a fourth hydrogen permeable membrane in fluid communication with the interior of the fourth battery cell. The fourth hydrogen permeable membrane is configured to selectively allow any hydrogen generated in the fourth cell to pass from inside the fourth cell to outside the fourth cell through the fourth hydrogen permeable membrane while substantially preventing other fluids from passing through the fourth hydrogen permeable membrane.

[0013] In some embodiments, the first hydrogen sensor is in fluid communication with the second hydrogen permeable membrane, the third hydrogen permeable membrane, and the fourth hydrogen permeable membrane. The first hydrogen sensor is configured to detect the presence of hydrogen that has passed through the second hydrogen permeable membrane, the third hydrogen permeable membrane, the fourth hydrogen permeable membrane, or a combination thereof. The first hydrogen sensor is adjacent to the first hydrogen sensor.

[0014] In some embodiments, the battery system further comprises a battery management system in communication with the first hydrogen sensor. The battery management system is operable to determine a hydrogen concentration and / or a rate of change of the hydrogen concentration with respect to time in response to the presence of hydrogen detected by the first hydrogen sensor. The battery management system is operable to compare the concentration and / or the rate of change with a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold.

[0015] In some embodiments, the battery management system is operable to direct a control action in response to the concentration and / or rate of change exceeding a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold. The control action includes sending a warning notification to a receiving device.

[0016] In some embodiments, the battery system is operably disposed in a vehicle.

[0017] In some embodiments, the hydrogen permeable membrane has a hydrogen selectivity value of at least 99.0%.

[0018] In some embodiments, the hydrogen permeable membrane is selected from the group consisting of polymers, porous ceramics / carbons, dense ceramics, dense metals, and combinations thereof.

[0019] In some embodiments, the dense metal includes palladium.

[0020] In some embodiments, the first battery cell is selected from a pouch cell, a square cell, or a cylindrical cell.

[0021] According to an alternative embodiment, a battery system includes a battery module. The battery module includes a battery cell management device, a hydrogen sensor communicating with the battery cell management device, and a plurality of battery cells. Each battery cell includes a battery cell housing arranged around the interior of the battery cell, and at least one multilayer stack. The multilayer stack is disposed inside the battery cell and includes a cathode, an anode, and a separator disposed between the anode and the cathode. The battery system also includes a corresponding hydrogen permeable membrane in fluid communication with the interior of the battery cell. The corresponding hydrogen permeable membrane is configured to selectively allow any hydrogen gas generated in the corresponding battery cell to pass through the corresponding hydrogen permeable membrane from the interior of the battery cell to the outside of the corresponding battery cell, while substantially preventing other fluids from passing through the corresponding hydrogen permeable membrane. The hydrogen sensor is in fluid communication with the hydrogen permeable membrane of each battery cell and is configured to detect the presence of hydrogen that has passed through the hydrogen permeable membrane and is close to the hydrogen sensor. The battery cell management device is operable to determine the hydrogen concentration and / or the rate of change of the hydrogen concentration relative to time in response to the presence of hydrogen detected by the hydrogen sensor. The battery cell management device is operable to compare the concentration and / or the rate of change with a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold.

[0022] According to an alternative embodiment, the battery system includes a battery pack. The battery pack includes a battery management system and a plurality of battery modules. Each battery module includes a hydrogen sensor and a plurality of battery cells. Each battery cell includes a battery cell housing arranged around the inside of the battery cell, and at least one multilayer stack. The multilayer stack is disposed inside the battery cell and includes a cathode, an anode, and a separator disposed between the anode and the cathode and a corresponding hydrogen permeable membrane. The corresponding hydrogen permeable membrane is in fluid communication with the inside of the battery cell and is configured to selectively allow any hydrogen gas generated in the corresponding battery cell to reach the outside of the corresponding battery cell from the inside of the battery cell through the corresponding hydrogen permeable membrane while substantially preventing other fluids from passing through the corresponding hydrogen permeable membrane. The hydrogen sensor is in fluid communication with the hydrogen permeable membrane of each battery cell and is configured to detect the presence of hydrogen that has passed through the hydrogen permeable membrane of each battery cell. The hydrogen permeable membrane of each battery cell is adjacent to the hydrogen sensor. The hydrogen sensor communicates with the battery management system. The battery management system is operable to determine the hydrogen concentration of each module and / or the rate of change of the hydrogen concentration relative to time in response to the presence of hydrogen detected by the corresponding hydrogen sensor. The battery management system is operable to compare the concentration and / or the rate of change with a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold.

[0023] In some embodiments, the battery system is operably disposed in a vehicle.

[0024] The present invention provides the following technical solutions:

[0025] 1. A battery system comprising:

[0026] A first battery unit comprises:

[0027] a first battery cell housing disposed around an interior of the first battery cell; and

[0028] at least one first multilayer stack disposed within the first battery cell and comprising a first cathode, a first anode, and a first separator disposed between the first anode and the first cathode; and

[0029] A first hydrogen permeable membrane is in fluid communication with the interior of the first battery cell and is configured to selectively allow any hydrogen generated in the first battery cell to pass from the interior of the first battery cell to the exterior of the first battery cell through the first hydrogen permeable membrane while substantially preventing other fluids from passing through the first hydrogen permeable membrane.

[0030] 2. The battery system according to claim 1 further comprises a first hydrogen sensor in fluid communication with the first hydrogen permeable membrane and configured to detect the presence of hydrogen that has passed through the first hydrogen permeable membrane and is close to the first hydrogen sensor.

[0031] 3. The battery system of claim 2, wherein the first hydrogen sensor is configured to detect the presence of hydrogen in an amount of about 1 ppm to about 1000 ppm or greater.

[0032] 4. The battery system according to solution 2 further includes a first battery module, the first battery module includes a first plurality of battery cells, the first plurality of battery cells include the first battery cell and a second battery cell, wherein the second battery cell includes:

[0033] a second battery cell housing defined and disposed about an interior of a second battery cell; and

[0034] at least one second multilayer stack disposed within the second battery cell and comprising a second cathode, a second anode, and a second separator disposed between the second anode and the second cathode; and

[0035] a second hydrogen permeable membrane in fluid communication with the interior of the second battery cell and configured to selectively allow any hydrogen generated in the second battery cell to pass from the interior of the second battery cell through the second hydrogen permeable membrane to the exterior of the second battery cell while substantially preventing other fluids from passing through the second hydrogen permeable membrane.

[0036] 5. The battery system according to claim 4, wherein the first hydrogen sensor is in fluid communication with the second hydrogen permeable membrane and is configured to detect the presence of hydrogen that has passed through the second hydrogen permeable membrane and is close to the first hydrogen sensor.

[0037] 6. The battery system according to Option 5 also includes a battery cell management device, which communicates with the first hydrogen sensor and is operable to determine the hydrogen concentration and / or the rate of change of the hydrogen concentration with respect to time in response to the presence of hydrogen detected by the first hydrogen sensor, and compare the concentration and / or the rate of change with a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold.

[0038] 7. A battery system according to Option 6, wherein the battery cell management device is operable to indicate a control action in response to the concentration and / or change rate exceeding a corresponding predetermined concentration threshold and / or a corresponding predetermined change rate threshold, wherein the control action includes sending a warning notification to a receiving device.

[0039] 8. A battery system according to Option 7, wherein the receiving device includes a battery management system.

[0040] 9. The battery system according to solution 4 further includes a battery pack, the battery pack includes a plurality of battery modules, the plurality of battery modules include the first battery module and a second battery module, wherein the second battery module includes a second plurality of battery cells, the second plurality of battery cells include a third battery cell and a fourth battery cell, wherein the third battery cell includes:

[0041] a third battery cell housing defined and disposed about an interior of a third battery cell; and

[0042] at least one third multilayer stack disposed inside the third battery cell and comprising a third cathode, a third anode, and a third separator disposed between the third anode and the third cathode; and

[0043] a third hydrogen permeable membrane in fluid communication with the interior of the third battery cell and configured to selectively allow any hydrogen generated in the third battery cell to pass from the interior of the third battery cell through the third hydrogen permeable membrane to the exterior of the third battery cell while substantially preventing other fluids from passing through the third hydrogen permeable membrane, wherein the fourth battery cell comprises:

[0044] a fourth battery cell housing defining a fourth battery cell interior and disposed around the fourth battery cell interior; and

[0045] at least one fourth multilayer stack disposed within the fourth battery cell and comprising a fourth cathode, a fourth anode, and a fourth separator disposed between the fourth anode and the fourth cathode; and

[0046] a fourth hydrogen permeable membrane in fluid communication with the interior of the fourth battery cell and configured to selectively allow any hydrogen gas generated in the fourth battery cell to pass from the interior of the fourth battery cell through the fourth hydrogen permeable membrane to the exterior of the fourth battery cell while substantially preventing other fluids from passing through the fourth hydrogen permeable membrane.

[0047] 10. A battery system according to Option 9, wherein the first hydrogen sensor is in fluid communication with the second hydrogen permeable membrane, the third hydrogen permeable membrane, and the fourth hydrogen permeable membrane, and is configured to detect the presence of hydrogen that has passed through the second hydrogen permeable membrane, the third hydrogen permeable membrane, the fourth hydrogen permeable membrane, or a combination thereof and is close to the first hydrogen sensor.

[0048] 11. The battery system according to Option 10 also includes a battery management system, which communicates with the first hydrogen sensor and is operable to determine the hydrogen concentration and / or the rate of change of the hydrogen concentration with respect to time in response to the presence of hydrogen detected by the first hydrogen sensor, and compare the concentration and / or the rate of change with a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold.

[0049] 12. A battery system according to scheme 11, wherein the battery management system is operable to indicate a control action in response to the concentration and / or the rate of change exceeding a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold, wherein the control action includes sending a warning notification to a receiving device.

[0050] 13. A battery system according to Option 1, wherein the battery system is operably disposed in a vehicle.

[0051] 14. The battery system according to claim 1, wherein the hydrogen permeable membrane has a hydrogen selectivity value of at least 99.0%.

[0052] 15. A battery system according to Option 1, wherein the hydrogen permeable membrane is selected from polymers, porous ceramics / carbon, dense ceramics, dense metals and combinations thereof.

[0053] 16. A battery system according to embodiment 15, wherein the dense metal comprises palladium.

[0054] 17. A battery system according to Option 1, wherein the first battery cell is selected from a soft-pack battery, a square battery or a cylindrical battery.

[0055] 18. A battery system comprising:

[0056] A battery module, the battery module comprising a battery cell management device, a hydrogen sensor communicating with the battery cell management device, and a plurality of battery cells, each battery cell comprising:

[0057] a battery cell housing disposed around the interior of the battery cell; and

[0058] at least one multilayer stack disposed within the battery cell and comprising a cathode, an anode, and a separator disposed between the anode and the cathode; and

[0059] a respective hydrogen permeable membrane in fluid communication with the interior of the battery cell and configured to selectively allow any hydrogen gas generated in the respective battery cell to pass from the interior of the battery cell through the respective hydrogen permeable membrane to the exterior of the respective battery cell while substantially preventing other fluids from passing through the respective hydrogen permeable membrane; and

[0060] wherein the hydrogen sensor is in fluid communication with the hydrogen permeable membrane of each battery cell and is configured to detect the presence of hydrogen that has passed through the hydrogen permeable membrane and is proximate to the hydrogen sensor,

[0061] In which, the battery cell management device is operable to determine the hydrogen concentration and / or the rate of change of the hydrogen concentration with respect to time in response to the presence of hydrogen detected by the hydrogen sensor, and compare the hydrogen concentration and / or the rate of change with the corresponding predetermined concentration threshold and / or the corresponding predetermined rate of change threshold.

[0062] 19. A battery system comprising:

[0063] A battery pack, the battery pack comprising a battery management system and a plurality of battery modules, each battery module comprising a hydrogen sensor and a plurality of battery cells, each battery cell comprising:

[0064] a battery cell housing defining and disposed about the battery cell interior; and

[0065] at least one multilayer stack disposed within the battery cell and comprising a cathode, an anode, and a separator disposed between the anode and the cathode; and

[0066] a respective hydrogen permeable membrane in fluid communication with the interior of the battery cell and configured to selectively allow any hydrogen gas generated in the respective battery cell to pass from the interior of the battery cell through the respective hydrogen permeable membrane to the exterior of the respective battery cell while substantially preventing other fluids from passing through the respective hydrogen permeable membrane; and

[0067] wherein the hydrogen sensor is in fluid communication with the hydrogen permeable membrane of each battery cell and is configured to detect the presence of hydrogen that has passed through the hydrogen permeable membrane of each battery cell and is proximate to the hydrogen sensor,

[0068] wherein the hydrogen sensor communicates with a battery management system; and

[0069] In which, the battery management system is operable to determine the hydrogen concentration and / or the rate of change of the hydrogen concentration with respect to time for each module in response to the presence of hydrogen detected by the corresponding hydrogen sensor, and compare the hydrogen concentration and / or the rate of change with the corresponding predetermined concentration threshold and / or the corresponding predetermined rate of change threshold.

[0070] 20. A battery system according to Option 19, wherein the battery system is operably disposed in a vehicle.

[0071] The above features and advantages and other features and advantages of the present disclosure are readily apparent from the following detailed description of the best modes for carrying out the disclosure when taken in connection with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0072] Figure 1-Figure 3 is a schematic diagram of a battery system including a battery cell according to one or more embodiments of the present disclosure.

[0073] Figure 4 is a schematic top view of a battery system including a battery module according to one or more embodiments of the present disclosure.

[0074] Figure 5is a schematic top view of a battery system including a battery pack having a hydrogen sensor according to one or more embodiments of the present disclosure.

[0075] Figure 6 is a schematic top view of a battery system including a battery pack having a plurality of hydrogen sensors according to one or more embodiments of the present disclosure.

[0076] The accompanying drawings are not necessarily drawn to scale and may present somewhat simplified representations of various preferred features of the present disclosure disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes. Details related to these features will be determined in part by the specific intended application and use environment. DETAILED DESCRIPTION

[0077] As required, specific embodiments of the present invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely examples of the present disclosure that may be implemented in various and alternative forms. The drawings are not necessarily drawn to scale; certain features may be enlarged or minimized to show details of particular components. Therefore, the specific structural and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to adopt the present disclosure in different ways.

[0078] Unless otherwise specifically indicated from the context, as used herein, the term "about" should be understood to be within the normal tolerance range in the art, such as within 2 standard deviations of the mean. "About" can be understood to be within 10%, 5%, 1%, 0.5%, 0.1%, 0.05% or 0.01% of the stated value. "About" can alternatively be understood to imply the exact value specified. Unless the context clearly indicates otherwise, the numerical values ​​provided herein are modified by the term "about".

[0079] Battery systems are designed to store electricity and generate electricity for use in applications such as electric vehicles, consumer products (e.g., laptops, tablets, mobile phones), and energy storage systems (e.g., systems that provide power to homes, hospitals, data centers, entire cities, or the general power grid). Battery systems include battery cells, which are electrochemical cells that generate electricity through chemical reactions and are responsible for storing and supplying electrical energy.

[0080] Battery cells are classified as primary batteries (i.e., non-rechargeable batteries) or secondary batteries (i.e., rechargeable batteries). In the case of rechargeable batteries (e.g., lithium-ion batteries, sodium-ion batteries, etc.), the chemical reaction that produces electricity can be reversed by applying an electric current (i.e., electrical energy) to the rechargeable battery; thus, the rechargeable battery is recharged and the electrical energy is stored as chemical energy.

[0081] A battery system may use battery modules or battery packs to meet the specific energy requirements of an application. A battery module includes multiple battery cells electrically connected in series and / or parallel to achieve a desired voltage and energy capacity. A battery pack includes multiple battery modules electrically connected in series and / or parallel to achieve a desired voltage and energy capacity.

[0082] A battery system may use a battery management unit (CMU), a battery management system (BMS), or a combination thereof to monitor and manage the condition of the battery cells. The CMU monitors and manages the parameters of the battery cells, such as voltage, current, internal temperature, and ambient temperature. The CMU is used in conjunction with the battery module to collect data about the condition of the battery cells. The BMS also monitors and manages the parameters of the battery cells and is used in conjunction with the battery pack. Data about the condition of the battery cells can be input directly into the BMS or from the CMU, depending on the battery system configuration. The data is collected through battery sensors, which measure the condition of the battery cells, such as temperature, voltage, current, etc.

[0083] Using this data, the battery system can manage the battery cells, for example, by diverting resources to or from the battery cells based on the condition of the battery cells. For example, if a battery cell in a particular module overheats, the battery system can supply additional cooling resources to the battery cells to reduce the temperature of the overheated battery cell, or can reduce the current supplied to or generated by the overheated battery cell.

[0084] The battery system can also identify bad cells. For example, a battery cell may not function after the manufacturing process due to mechanical, electrical or thermal battery abuse.

[0085] A bad battery may lead to thermal runaway. Thermal runaway describes a phenomenon in which increased thermal energy (i.e., heat) promotes and accelerates uncontrollable chemical reactions, resulting in rapid degradation of the battery cell. In other words, thermal runaway describes the process by which a battery cell enters an uncontrollable self-heating state, which may lead to battery venting.

[0086] Battery cells (including primary and secondary batteries) may be susceptible to thermal runaway. For example, lithium-ion batteries may be susceptible to thermal runaway.

[0087] In one example, thermal runaway occurs in stages: (1) onset of overheating, (2) heat accumulation and gas release, and (3) rapid development of abnormal conditions. The first stage of overheating occurs when the battery cell begins to overheat. Overheating causes changes in battery cell components and leads to unwanted chemical reactions.

[0088] During the heat accumulation and gas release phase, the decomposition of the battery cell components and the exothermic chemical reactions occurring within the battery cell produce gases (e.g., hydrogen, oxygen, carbon monoxide, and carbon dioxide) within the sealed battery cell. These gases increase the heat and pressure of the battery cell, further driving the chemical reactions within the battery cell until abnormal conditions occur. In addition, during the heat accumulation and gas release phase, the battery cell may pose a thermal threat to adjacent battery cells and may cause thermal runaway in adjacent battery cells.

[0089] Abnormal conditions may cause thermal damage to the inside and outside of the battery cell. Abnormal conditions may also cause rapid expansion and loss of the battery cell structure.

[0090] Although the battery system can identify a bad battery cell, the battery system is not equipped with a device for early detection of abnormalities in the battery cell. As a result, the time between the battery system identifying the abnormal battery cell and the abnormal battery cell experiencing thermal runaway may be extremely short.

[0091] Therefore, it is desirable to provide a battery system that solves one or more of the aforementioned problems, the battery system comprising a battery pack, a battery module, a battery cell, and a hydrogen permeable membrane in fluid communication with the battery cell. In addition, other desirable features and characteristics of the various embodiments described herein will become apparent from the following detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background.

[0092] The present disclosure relates generally to battery systems, and more particularly, to battery systems including a battery cell and a hydrogen permeable membrane in fluid communication with the battery cell.

[0093] In one or more embodiments of the present disclosure, a battery system includes a first battery cell. The first battery cell includes a first battery cell housing disposed around the interior of the first battery cell, and at least one first multilayer stack. The first multilayer stack is disposed inside the first battery cell and includes a first cathode, a first anode, and a first separator disposed between the first anode and the first cathode. The battery system also includes a first hydrogen permeable membrane in fluid communication with the interior of the first battery cell. The first hydrogen permeable membrane is configured to selectively allow any hydrogen generated in the first battery cell to pass through the first hydrogen permeable membrane from the interior of the first battery cell to the outside of the first battery cell, while substantially preventing other fluids from flowing through the first hydrogen permeable membrane.

[0094] In one or more embodiments of the present disclosure, a battery system includes a battery module. The battery module includes a plurality of battery cells. Each battery cell includes a battery cell housing and at least one multilayer stack disposed around the interior of the battery cell. The multilayer stack is disposed inside the battery cell and includes a cathode, an anode, and a separator disposed between the anode and the cathode.

[0095] The battery system also includes a plurality of hydrogen permeable membranes, wherein each hydrogen permeable membrane is in fluid communication with the interior of a corresponding one of the battery cells and is configured to selectively allow any hydrogen gas generated in the corresponding one of the battery cells to pass from the interior of the corresponding one of the battery cells through the corresponding one of the hydrogen permeable membranes to the exterior of the corresponding one of the battery cells, while substantially preventing other fluids from passing through the corresponding one of the hydrogen permeable membranes.

[0096] The battery system also includes a hydrogen sensor in fluid communication with the plurality of hydrogen permeable membranes and configured to detect the presence of hydrogen that has passed through the one or more hydrogen permeable membranes and is proximate to the hydrogen sensor.

[0097] The battery system also includes a cell management device that communicates with the hydrogen sensor and is operable to determine a hydrogen concentration and / or a rate of change of the hydrogen concentration with respect to time in response to the presence of hydrogen detected by the hydrogen sensor and compare the concentration and / or the rate of change to a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold. The predetermined concentration threshold may range from about 100 parts per million (ppm) to about 500 ppm or greater. The predetermined rate of change threshold may range from about 20 ppm per minute to about 100 ppm per minute or greater.

[0098] In one or more embodiments of the present disclosure, a battery system includes a battery pack including a plurality of battery modules and a hydrogen sensor in fluid communication with the battery modules. Each battery module includes a plurality of battery cells and a plurality of hydrogen permeable membranes, each hydrogen permeable membrane corresponding to a battery cell. Each battery cell includes a battery cell housing arranged around the interior of the battery cell, and at least one multilayer stack. The multilayer stack is arranged inside the battery cell and includes a cathode, an anode, and a separator arranged between the anode and the cathode. Each hydrogen permeable membrane is in fluid communication with a corresponding battery cell interior, and is configured to selectively allow any hydrogen generated in a corresponding battery cell to pass from the interior of a corresponding battery cell through a corresponding hydrogen permeable membrane to the outside of a corresponding battery cell, while substantially preventing other fluids from passing through a corresponding hydrogen permeable membrane. The hydrogen sensor is in fluid communication with a plurality of hydrogen permeable membranes and is configured to detect the presence of hydrogen that has passed through one or more hydrogen permeable membranes and is close to the hydrogen sensor.

[0099] The battery system also includes a battery management system in communication with the hydrogen sensor and operable to determine a hydrogen concentration and / or a rate of change of the hydrogen concentration with respect to time in response to the presence of hydrogen detected by the hydrogen sensor and compare the concentration and / or the rate of change with a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold. The predetermined concentration threshold may be in the range of about 100 ppm to about 500 ppm or more. The predetermined rate of change threshold may range from about 20 ppm per minute to about 100 ppm per minute or more.

[0100] The battery system has many advantages. The battery system allows for early detection of abnormal conditions in the battery cell that may lead to thermal runaway. The battery system also allows for reduced swelling or internal pressure buildup as the battery cell ages because the hydrogen permeable membrane allows hydrogen gas generated within the battery cell to leave the battery cell. As the battery cell ages due to charge and discharge cycles, hydrogen gas is generated due to the decomposition of the battery cell components.

[0101] The battery system also provides a method for checking whether the battery cell is operating normally during the solid electrolyte interface (SEI) formation stage of the battery cell manufacturing process. During the manufacturing process, when the battery cell is charged and discharged, the SEI layer is formed on the anode by the decomposition products of the electrolyte. Hydrogen gas, which is one of the decomposition products, passes through the hydrogen permeable membrane to the outside of the battery cell and is detected by the hydrogen sensor. The detection of hydrogen gas indicates that the battery cell is operating normally.

[0102] Figure 1 A cross-sectional view of a battery system 10 including a battery cell 20 is shown. As shown and discussed below, the battery cell 20 is configured as a soft pack battery. The battery cell 20 includes a battery cell housing 30 that defines and is disposed around and surrounds the battery cell interior 40. Specifically, for a soft pack battery, the battery cell housing 30 may be formed, for example, of a flexible pouch-like material that is impermeable or acts as a barrier to fluids (e.g., liquids, such as electrolyte compositions) and various gases (e.g., hydrogen, oxygen, etc.). Non-limiting examples of pouch-like materials for battery cell housings of soft pack batteries include aluminum laminated film shells, etc.

[0103] In an exemplary embodiment, at least one multilayer stack 50 is disposed in the battery cell interior 40. As shown, the battery cell 20 may include two multilayer stacks 50, 51 disposed in the battery cell interior 40. However, it should be understood that the battery cell 20 may include a single multilayer stack or more than two multilayer stacks. Each multilayer stack 50 or 51 includes a cathode 52, an anode 56, and a separator 54 disposed between the anode 56 and the cathode 52.

[0104] The cathode 52 is an electrode where a reduction reaction occurs. Non-limiting examples of cathode-type materials for the cathode 52 include lithium cobalt oxide (LiCoO2) and lithium manganese oxide (LiMn2O4).

[0105] The anode 56 is an electrode where an oxidation reaction occurs. Non-limiting examples of anode-type materials for the anode 56 include graphite, carbon materials, silicon-based materials, and the like.

[0106] Each multilayer stack 50 or 51 may include an electrolyte (not shown) that facilitates the transport of ions (e.g., lithium ions) between the cathode 52 and the anode 56. The electrolyte may be disposed between the anode 56 and the separator 54 and between the cathode 52 and the separator 54. Non-limiting examples of the electrolyte include a liquid electrolyte (e.g., LiPF6LiBF4, LiClO4, etc.) or a solid ceramic electrolyte (e.g., lithium metal oxide, etc.).

[0107] The multilayer stack 50 may include a pair of current collectors (e.g., a positive current collector 42 and a negative current collector 46). A cathode 52, a separator 54, an anode 56, and an electrolyte (not shown) may be disposed between the pair of current collectors 42, 46. The cathode 52 may be in electrical communication with the positive current collector 42. The anode 56 may be in electrical communication with the negative current collector 46.

[0108] The battery system 10 also includes a hydrogen permeable membrane 60 in fluid communication with the cell interior 40. The hydrogen permeable membrane 60 is configured to selectively allow any hydrogen (i.e., hydrogen gas) generated in the cell 20 to pass from the cell interior 40 through the hydrogen permeable membrane 60 to the exterior of the cell 20, while substantially preventing other fluids from passing through the hydrogen permeable membrane 60. Preventing other fluids from passing through the hydrogen permeable membrane 60 allows the cell 20 to operate normally. Examples of other fluids may include internal fluids (e.g., electrolyte compositions) and external fluids (e.g., water and other contaminants).

[0109] The hydrogen permeable membrane 60 may have a hydrogen selectivity value of at least 99.0% (e.g., allowing hydrogen to pass through while substantially preventing fluids other than hydrogen from passing through the membrane 60). For example, the hydrogen permeable membrane 60 may have a hydrogen selectivity of at least 99.5%, or at least 99.8%, or at least 99.9%. Thus, no more than 1% of fluids other than hydrogen pass through the membrane 60, such as no more than 0.5%, such as no more than 0.2%, such as no more than 0.1%. Thus, the hydrogen selectivity value is understood to indicate the amount of hydrogen that passes through the hydrogen permeable membrane 60 relative to other fluids. Hydrogen selectivity is defined as the amount of hydrogen that permeates or passes through the membrane per the total amount of fluid that permeates through the membrane.

[0110] The hydrogen permeable membrane 60 may be selected from polymers, porous ceramics / carbons, dense ceramics, dense metals, etc. The dense metal may include palladium. The hydrogen permeable membrane 60 may be integrated into a portion of the battery cell housing 30 or may replace a portion of the battery cell housing 30.

[0111] The battery system 10 also includes a hydrogen sensor 70 in fluid communication with the hydrogen permeable membrane 60 and configured to detect the presence of hydrogen that has passed through the hydrogen permeable membrane 60 and is proximate to the hydrogen sensor 70. The sensor 70 is configured to detect the presence of hydrogen in an amount from about 1 ppm to about 1000 ppm or greater. The hydrogen sensor 70 may include a microfabricated point contact hydrogen sensor for detecting hydrogen.

[0112] Under adverse conditions (i.e., extreme heat) or during operation (i.e., when the battery system 10 is stored or powered), the cell interior 40 may generate hydrogen gas within the cell interior 40. The hydrogen gas may travel through the cell interior 40 and through the hydrogen permeable membrane 60 to the exterior of the cell 20. Once outside the cell 20, the hydrogen gas is detected by the hydrogen sensor 70.

[0113] In one example, the battery cell 20 may generate hydrogen gas due to anomalies caused by mechanical abuse, electrical abuse, or thermal abuse in the battery cell 20. Any abuse may cause a short circuit of the battery cell 20 and ultimately lead to thermal runaway.

[0114] Figure 2 A cross-sectional view of a battery system 10 including a battery cell 80 is shown. As shown and discussed below, in this example, the battery cell 80 can be configured as a cylindrical battery. The battery cell 80 includes a battery cell housing 81, which defines and is disposed around and surrounds a battery cell interior 82. Specifically, for cylindrical batteries, the battery cell housing 81 can be formed, for example, of a nickel-plated steel material that is impermeable or acts as a barrier to fluids (e.g., liquids, such as electrolyte compositions) and various gases (e.g., hydrogen, oxygen, etc.). Non-limiting examples of cylindrical materials for the battery cell housing 81 of cylindrical batteries include nickel-plated steel, aluminum, and the like.

[0115] In the exemplary embodiment, at least one multilayer stack 83 is disposed within the battery cell interior 82. The multilayer stack includes a cathode 85, an anode 87, and a separator 86 disposed between the cathode 85 and the anode 87. It should be understood that the battery cell 20 may include a single multilayer stack or more than two multilayer stacks.

[0116] Each multilayer stack 83 or 84 may include an electrolyte (not shown) that facilitates the transport of ions (e.g., lithium ions) between the cathode 85 and the anode 87. The electrolyte may be disposed between the anode 87 and the separator 86 and between the cathode 85 and the separator 86. Non-limiting examples of the electrolyte include liquid electrolytes (e.g., LiPF6LiBF4, LiClO4, etc.) and solid ceramic electrolytes (e.g., lithium metal oxides, etc.).

[0117] As shown, in an exemplary embodiment, the hydrogen permeable membrane 60 can be located or disposed where hydrogen gas may accumulate, such as at the battery cover 86 of the battery cell 80. The hydrogen permeable membrane 60 can be integrated into a portion of the battery cover 86 or can replace a portion of the battery cover 86. For example, the hydrogen permeable membrane 60 can replace or be integrated into a current interrupt device (CID) (not shown) and a pressure relief valve (PRV) device (not shown). Alternatively, the hydrogen permeable membrane 60 can be integrated into a portion of the battery cell housing 81 or can replace a portion of the battery cell housing 81.

[0118] During operation, when the battery cell 80 is discharged or charged, the battery cell interior 82 may generate hydrogen gas within the battery cell interior 82. The hydrogen gas may travel through the battery cell interior 82 and through the hydrogen permeable membrane 60 to the exterior of the battery cell 80. Once outside the battery cell 80, the hydrogen is detected by the hydrogen sensor 70.

[0119] Figure 3 A cross-sectional view of a battery system 10 including a battery cell 90 is shown. As shown and discussed below, in this example, the battery cell 90 can be configured as a square battery. The battery cell 90 includes a battery cell housing 91, which is disposed around and surrounds the battery cell interior 92. Specifically, for square batteries, the battery cell housing 91 can be formed, for example, of an aluminum material that is impermeable or serves as a barrier to fluids (e.g., liquids, such as electrolyte compositions) and various gases (e.g., hydrogen, oxygen, etc.). Non-limiting examples of cylindrical materials for the battery cell housing 91 for cylindrical batteries include aluminum, aluminum alloys, steel, plastics, and the like.

[0120] In the exemplary embodiment, at least one multilayer stack 93 is disposed within the battery cell interior 92. The multilayer stack includes a cathode 95, an anode 97, and a separator 96 disposed between the cathode 95 and the anode 97. It should be understood that the battery cell 20 may include a single multilayer stack or more than two multilayer stacks.

[0121] Each multilayer stack 93 or 94 may include an electrolyte (not shown) that facilitates the transport of ions (e.g., lithium ions) between the cathode 95 and the anode 97. The electrolyte may be disposed between the anode 97 and the separator 96 and between the cathode 95 and the separator 96. Non-limiting examples of the electrolyte include liquid electrolytes (e.g., LiPF6LiBF4, LiClO4, etc.) and solid ceramic electrolytes (e.g., lithium metal oxides, etc.).

[0122] As shown, in an exemplary embodiment, hydrogen permeable membrane 60 may be located or disposed where hydrogen gas may accumulate, such as at the top of battery cell 90 adjacent to pressure relief membrane 96. Hydrogen permeable membrane 60 may be integrated into a portion of battery cell housing 91 or may replace a portion of battery cell housing 91.

[0123] Under adverse conditions (i.e., extreme heat) or during operation (i.e., when the battery system 10 is stored or powered), the battery cell interior 92 may generate hydrogen gas within the battery cell interior 92. The hydrogen gas may travel through the battery cell interior 92 and through the hydrogen permeable membrane 60 to the exterior of the battery cell 90. Once outside the battery cell 20, the hydrogen is detected by the hydrogen sensor 70.

[0124] although Figure 1 , Figure 2 and Figure 3 Soft pack batteries (battery cell 20), cylindrical batteries (battery cell 80) and square batteries (battery cell 90) are shown separately, but the battery system 10 may include other types of batteries. The battery system 10 may include any electrochemical cell (or electrochemical device) that generates electrical energy from a chemical reaction.

[0125] Figure 4 1 is a schematic top view of a battery system 10 including a battery module 100 according to one or more embodiments of the present disclosure. The battery module 100 includes a plurality of battery cells 110, including a battery cell 20 and a battery cell 120. Similar to the battery cell 20, the battery cell 120 includes a battery cell housing 130 that defines a battery cell interior 140 and is disposed around the battery cell interior 140, and at least one multilayer stack 150 disposed in the battery cell interior 140. The multilayer stack 150 includes a cathode 152, an anode 156, and a separator 154 disposed between the anode 156 and the cathode 152.

[0126] The battery system 10 also includes a hydrogen permeable membrane 160 that is in fluid communication with the cell interior 140 and is configured to selectively allow any hydrogen gas generated in the cell 120 to pass from the cell interior 140 through the hydrogen permeable membrane 160 to the exterior of the cell 120 while substantially preventing other fluids from passing through the hydrogen permeable membrane 160 .

[0127] The hydrogen sensor 70 is in fluid communication with the hydrogen permeable membrane 160 and is configured to detect the presence of hydrogen that has passed through the hydrogen permeable membrane 160 and is proximate to the hydrogen sensor 70 .

[0128] The battery system 10 also includes a cell management device 170 that communicates with the hydrogen sensor 70 and is operable to determine at least one of a hydrogen concentration and a rate of change of the hydrogen concentration with respect to time in response to detecting the presence of hydrogen by the hydrogen sensor 70, and compare at least one of the concentration and the rate of change with at least one of a corresponding predetermined concentration threshold and a corresponding predetermined rate of change threshold. The predetermined concentration threshold may be in the range of about 100 ppm to about 500 ppm or more. The predetermined rate of change threshold may range from about 20 ppm per minute to about 100 ppm per minute or more.

[0129] The battery cell management device 170 is operable to direct a control action in response to the concentration and / or rate of change exceeding a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold. The control action may include sending a warning notification to a receiving device, such as Figure 4 Battery management system 180 is shown. Examples of receiving devices may include a battery management system (BMS), a user computer and / or interface for a vehicle, an energy storage system, or any other system that can receive power from battery cell 120.

[0130] The battery cell management device 170 may be a microcontroller-based sensor array mounted on a printed circuit board (PCB). The battery cell management device 170 may have a GPS transceiver and RF capabilities and may be packaged on or in the battery module 100 .

[0131] Under adverse conditions (i.e., extreme heat) or during operation (i.e., when the battery system 10 is stored or powered), the battery cell 120 may generate hydrogen gas within the battery cell interior 130. The hydrogen gas may travel through the battery cell interior 130 and pass through the hydrogen permeable membrane 160 to the exterior of the battery cell 120. Once outside the battery cell 120, the hydrogen is detected by the hydrogen sensor 70. Although the battery cell 120 is used as an illustrative example of releasing hydrogen under adverse conditions or operation, any battery cell in the plurality of battery cells 110 may experience the release of hydrogen, which is detected by the hydrogen sensor 70.

[0132] The hydrogen sensor 70 transmits information (e.g., data about hydrogen gas) to the battery cell management device 170. The battery cell management device 170 determines the hydrogen concentration and / or the rate of change of the hydrogen concentration with respect to time in response to the presence of hydrogen detected by the hydrogen sensor 70. The battery cell management device 170 compares the concentration and / or the rate of change with a predetermined concentration threshold and / or a predetermined rate of change threshold. If the concentration threshold and / or the rate of change threshold are met, the battery cell management device 170 performs one or more control actions, wherein the control action includes sending a warning notification to a receiving device (e.g., the battery management system 180). The predetermined concentration threshold may be in the range of about 100 ppm to about 500 ppm or greater. The predetermined rate of change threshold may range from about 20 ppm per minute to about 100 ppm per minute or greater.

[0133] Figure 5 1 is a schematic top view of a battery system 10 including a battery pack having a hydrogen sensor 70 according to one or more embodiments of the present disclosure. The battery system 10 also includes a battery pack 190, and the battery pack 190 includes a plurality of battery modules 200. The plurality of battery modules 200 include a battery module 100 and a battery module 210. The battery module 210 includes a plurality of battery cells 220, and the battery cells 220 include a battery cell 230 and a battery cell 270.

[0134] Although the components of the battery cell 230 are not Figure 5 However, Figure 1-3 The same reference numerals in the Figure 5 The battery cell 230 includes a battery cell housing that defines and surrounds the interior of the battery cell and at least one multilayer stack disposed within the battery cell. The multilayer stack of the battery cell 230 may include a cathode, an anode, and a separator disposed between the anode and the cathode. It should be understood that the battery cell 230 may include one or more multilayer stacks.

[0135] The battery system 10 also includes a hydrogen permeable membrane 260 in fluid communication with the cell interior of the battery cell 230. The hydrogen permeable membrane 260 is configured to selectively allow any hydrogen gas generated in the battery cell 230 to pass from the cell interior through the hydrogen permeable membrane 260 to the exterior of the battery cell 230 while substantially preventing other fluids from passing through the hydrogen permeable membrane 260.

[0136] Although the components of the battery cell 270 are not Figure 5 , but the battery cell 270 includes a battery cell housing disposed around the interior of the battery cell and at least one multilayer stack disposed inside the battery cell. The multilayer stack may include a cathode, an anode, a separator, and an electrolyte disposed between the anode and the cathode. It should be understood that the battery cell 270 may include one or more multilayer stacks.

[0137] The battery system 10 also includes a hydrogen permeable membrane 300 in fluid communication with the cell interior of the battery cell 270. The hydrogen permeable membrane 300 is configured to selectively allow any hydrogen gas generated in the battery cell 270 to pass from the cell interior of the battery cell 270 through the hydrogen permeable membrane 300 to the exterior of the battery cell 270 while substantially preventing other fluids from passing through the hydrogen permeable membrane 300.

[0138] Hydrogen sensor 70 is in fluid communication with hydrogen permeable membranes 160, 260, and 300. Hydrogen sensor 70 is configured to detect the presence of hydrogen that has passed through hydrogen permeable membranes 160, 260, and / or 300 and is proximate to hydrogen sensor 70.

[0139] The hydrogen sensor 70 is also in fluid communication with the hydrogen permeable membrane of each of the plurality of battery cells within the plurality of battery modules of the battery stack 190. The hydrogen sensor 70 is configured to detect the presence of hydrogen that has passed through the hydrogen permeable membrane of each of the plurality of battery cells and is proximate to the hydrogen sensor 70.

[0140] The battery system 10 also includes a battery management system 180 in communication with the hydrogen sensor 70, which is operable to determine the hydrogen concentration and / or the rate of change of the hydrogen concentration with respect to time in response to detecting the presence of hydrogen by the hydrogen sensor 70 and compare the concentration and / or the rate of change with a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold. The predetermined concentration threshold may be in the range of about 100 ppm to about 500 ppm or more. The predetermined rate of change threshold may range from about 20 ppm per minute to about 100 ppm per minute or more.

[0141] The battery management system 180 is operable to direct a control action in response to the concentration and / or rate of change exceeding a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold, wherein the control action includes sending a warning notification to a receiving device. Examples of receiving devices may include user computers and / or interfaces for vehicles, energy storage systems, and any other systems that receive power from battery cells.

[0142] The battery management system 180 is configured to control functions of the battery system 10 , including but not limited to controlling switching of various battery modules or battery cells of the battery system 10 , monitoring operating parameters, diagnosing faults, etc. The battery management system 180 may also be configured to communicate with a plurality of battery modules 200 .

[0143] The battery management system 180 includes a processor (e.g., a central processing unit, a microprocessor, an application-specific integrated circuit, etc.) and a sufficient amount and type of memory, including tangible, non-transitory memory, such as read-only memory, optical memory, magnetic memory, flash memory, etc. The battery management system 180 also includes a sufficient amount of random access memory, electrically erasable programmable read-only memory, etc., as well as a high-speed clock, analog to digital and digital to analog circuits, input / output circuits and devices, and appropriate signal conditioning and buffering circuits.

[0144] Under adverse conditions (i.e., extreme heat) or during operation (i.e., when the battery system 10 is storing or supplying power), the battery cells 20 in the plurality of battery modules 200 of the battery pack 190 may generate hydrogen gas within the battery cell interior 40 of the battery cell 20. The hydrogen gas may travel through the battery cell interior 40 and through the hydrogen permeable membrane 60 to the exterior of the battery cell 20. Once outside the battery cell 20, the hydrogen gas is detected by the hydrogen sensor 70. The battery cell 20 is used for illustration purposes, but one or more battery cells may generate hydrogen gas.

[0145] The hydrogen sensor 70 transmits information (e.g., data about hydrogen) to the battery management system 180. The battery management system 180 determines the hydrogen concentration and / or the rate of change of the hydrogen concentration relative to time in response to the hydrogen sensor 70 detecting the presence of hydrogen. The battery management system 180 compares the concentration and / or the rate of change with a predetermined concentration threshold and / or a predetermined rate of change threshold. The predetermined concentration threshold may be in the range of about 100 ppm to about 500 ppm or more. The predetermined rate of change threshold may range from about 20 ppm per minute to about 100 ppm per minute or more.

[0146] If the concentration threshold and / or the rate of change threshold are met, the battery management system 180 performs one or more control actions, wherein the control action includes sending a warning notification to a receiving device. Examples of receiving devices may include user computers and / or interfaces for vehicles, energy storage systems, and any other systems that receive power from battery cells.

[0147] Figure 6 1 is a schematic top view of a battery system 10 including a battery pack 190 having a plurality of hydrogen sensors 320 according to one or more embodiments of the present disclosure. The battery system 10 includes a battery pack 190, which includes a battery management system 180 and a plurality of battery modules 200. Each battery module 200 includes a hydrogen sensor 320 and a plurality of battery cells. Each battery cell includes a battery cell housing disposed around the interior of the battery cell and at least one multilayer stack disposed inside the battery cell. The multilayer stack includes a cathode, an anode, and a separator disposed between the anode and the cathode. It should be understood that each battery cell 20 may include one or more multilayer stacks.

[0148] The battery system 10 also includes a corresponding hydrogen permeable membrane in fluid communication with the interior of the battery cell and is configured to selectively allow any hydrogen gas generated in the corresponding battery cell to pass from the interior of the battery cell through the corresponding hydrogen permeable membrane to the exterior of the corresponding battery cell while substantially preventing other fluids from passing through the corresponding hydrogen permeable membrane.

[0149] The respective hydrogen sensor is in fluid communication with the hydrogen permeable membrane of each battery cell of the respective battery module and is configured to detect the presence of hydrogen that has passed through the hydrogen permeable membrane of each battery cell and is proximate to the hydrogen sensor.

[0150] The respective hydrogen sensors 320 communicate with the respective cell management devices 310. The respective cell management devices 310 communicate with the battery management system 180. The battery management system 180 is operable to determine the hydrogen concentration and / or the rate of change of the hydrogen concentration with respect to time for each module in response to the presence of hydrogen detected by the respective hydrogen sensors, and compare the concentration and / or the rate of change with the respective predetermined concentration threshold and / or the respective predetermined rate of change threshold. The predetermined concentration threshold may be in the range of about 100 ppm to about 500 ppm or more. The predetermined rate of change threshold may range from about 20 ppm per minute to about 100 ppm per minute or more.

[0151] Under adverse conditions (i.e., extreme heat) or during operation (i.e., when the battery system 10 is stored or powered), the battery cells 20 in the plurality of battery modules 200 of the battery pack 190 may generate hydrogen gas within the battery cell interior 40 of the battery cell 20. The hydrogen gas may travel through the battery cell interior 40 and through the hydrogen permeable membrane 60 to the exterior of the battery cell 20. Once outside the battery cell 20, the hydrogen gas is detected by the hydrogen sensor 320. The battery cell 20 is used for illustration purposes, but one or more battery cells may generate hydrogen gas.

[0152] The hydrogen sensor 320 transmits information (e.g., data about hydrogen) to the corresponding battery cell management device 310, and the battery cell management device 310 transmits to the battery management system 180. The battery management system 180 determines the concentration of hydrogen and / or the rate of change of the concentration of hydrogen with respect to time in response to the presence of hydrogen gas detected by the hydrogen sensor 320. The battery management system 180 compares the concentration and / or the rate of change with a predetermined concentration threshold and / or a predetermined rate of change threshold. The predetermined concentration threshold may be in the range of about 100 ppm to about 500 ppm or more. The predetermined rate of change threshold may range from about 20 ppm per minute to about 100 ppm per minute or more.

[0153] If the concentration threshold and / or the rate of change threshold are met, the battery management system 180 performs one or more control actions, wherein the control action includes sending a warning notification to a receiving device. Examples of receiving devices may include user computers and / or interfaces for vehicles, energy storage systems, and any other systems that receive power from battery cells. Another control action may include supplying cooling resources to the battery cell when the battery cell is overheated.

[0154] In an exemplary embodiment, the battery system 10 is operably configured, incorporated, or otherwise used in a vehicle (e.g., a motor vehicle). As used herein, "vehicle" is understood to refer to a device configured to transport people, things, objects, etc. Non-limiting examples of motor vehicles (e.g., internal combustion engine (ICE) vehicles, electric vehicles including batteries, and fuel cell vehicles, etc.) include land vehicles (e.g., cars, trucks, motorcycles, electric bicycles, buses, trains, etc.), aircraft (e.g., airplanes, helicopters, unmanned aerial vehicles, etc.), water vehicles (e.g., ships, boats, etc.), and amphibious vehicles (e.g., hovercraft, etc.).

[0155] While the best modes for carrying out the disclosure have been described in detail, those familiar with the art to which this disclosure relates will recognize various alternative designs and embodiments for practicing the disclosure within the scope of the appended claims.

[0156] Any dimensions, configurations, etc. discussed herein may be varied as needed or desired from any values ​​or characteristics specifically mentioned herein or shown in the accompanying drawings for any embodiment.

[0157] It will be apparent to those skilled in the art that various modifications and variations may be made to the embodiments of the apparatus and assembly methods discussed herein without departing from the scope or spirit of the present disclosure. Other embodiments of the present disclosure will be apparent to those skilled in the art by considering the specification and the practice of the various embodiments disclosed herein. For example, the construction and function of some devices may be different from those described herein, and certain steps of any method may be omitted, performed in an order different from that specifically mentioned, or performed simultaneously or in various sub-steps in some cases. In addition, certain aspects or features of the various embodiments may be varied or modified to create additional embodiments, and the features and aspects of the various embodiments may be added to or substituted for other features or aspects of other embodiments to provide additional embodiments.

Claims

1. A battery system comprising: A first battery unit comprises: a first battery cell housing disposed around an interior of the first battery cell; and at least one first multilayer stack disposed within the first battery cell and comprising a first cathode, a first anode, and a first separator disposed between the first anode and the first cathode; and A first hydrogen permeable membrane is in fluid communication with the interior of the first battery cell and is configured to selectively allow any hydrogen generated in the first battery cell to pass from the interior of the first battery cell to the exterior of the first battery cell through the first hydrogen permeable membrane while substantially preventing other fluids from passing through the first hydrogen permeable membrane. 2 . The battery system of claim 1 , further comprising a first hydrogen sensor in fluid communication with the first hydrogen permeable membrane and configured to detect the presence of hydrogen that has passed through the first hydrogen permeable membrane and is proximate to the first hydrogen sensor.

3. The battery system according to claim 2, further comprising a first battery module, the first battery module comprising a first plurality of battery cells, the first plurality of battery cells comprising the first battery cell and a second battery cell, wherein the second battery cell comprises: a second battery cell housing defined and disposed about an interior of a second battery cell; and at least one second multilayer stack disposed within the second battery cell and comprising a second cathode, a second anode, and a second separator disposed between the second anode and the second cathode; and A second hydrogen permeable membrane is in fluid communication with the interior of the second battery cell and is configured to selectively allow any hydrogen generated in the second battery cell to pass from the interior of the second battery cell to the exterior of the second battery cell through the second hydrogen permeable membrane while substantially preventing other fluids from passing through the second hydrogen permeable membrane.

4. The battery system of claim 3, wherein the first hydrogen sensor is in fluid communication with the second hydrogen permeable membrane and is configured to detect the presence of hydrogen that has passed through the second hydrogen permeable membrane and is proximate to the first hydrogen sensor.

5. The battery system according to claim 4 further includes a battery cell management device, which communicates with the first hydrogen sensor and is operable to determine the hydrogen concentration and / or the rate of change of the hydrogen concentration with respect to time in response to the presence of hydrogen detected by the first hydrogen sensor, and compare the concentration and / or the rate of change with a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold.

6. The battery system according to claim 5, wherein: The battery cell management device is operable to indicate a control action in response to the concentration and / or rate of change exceeding a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold, wherein the control action includes sending a warning notification to a receiving device.

7. The battery system according to claim 3, further comprising a battery pack, the battery pack comprising a plurality of battery modules, the plurality of battery modules comprising the first battery module and a second battery module, wherein the second battery module comprises a second plurality of battery cells, the second plurality of battery cells comprises a third battery cell and a fourth battery cell, wherein, The third battery unit comprises: a third battery cell housing defined and disposed about an interior of a third battery cell; and at least one third multilayer stack disposed inside the third battery cell and comprising a third cathode, a third anode, and a third separator disposed between the third anode and the third cathode; and a third hydrogen permeable membrane in fluid communication with the interior of the third battery cell and configured to selectively allow any hydrogen generated in the third battery cell to pass from the interior of the third battery cell through the third hydrogen permeable membrane to the exterior of the third battery cell while substantially preventing other fluids from passing through the third hydrogen permeable membrane, wherein the fourth battery cell comprises: a fourth battery cell housing defining a fourth battery cell interior and disposed around the fourth battery cell interior; and at least one fourth multilayer stack disposed within the fourth battery cell and comprising a fourth cathode, a fourth anode, and a fourth separator disposed between the fourth anode and the fourth cathode; and a fourth hydrogen permeable membrane in fluid communication with the interior of the fourth battery cell and configured to selectively allow any hydrogen gas generated in the fourth battery cell to pass from the interior of the fourth battery cell through the fourth hydrogen permeable membrane to the exterior of the fourth battery cell while substantially preventing other fluids from passing through the fourth hydrogen permeable membrane.

8. The battery system of claim 7, wherein the first hydrogen sensor is in fluid communication with the second, third, and fourth hydrogen permeable membranes, and is configured to detect the presence of hydrogen that has passed through the second, third, fourth, or combinations thereof and is proximate to the first hydrogen sensor.

9. The battery system according to claim 8 further includes a battery management system, which communicates with the first hydrogen sensor and is operable to determine the hydrogen concentration and / or the rate of change of the hydrogen concentration with respect to time in response to the presence of hydrogen detected by the first hydrogen sensor, and compare the concentration and / or the rate of change with a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold.

10. The battery system of claim 9, wherein the battery management system is operable to indicate a control action in response to the concentration and / or the rate of change exceeding a corresponding predetermined concentration threshold and / or a corresponding predetermined rate of change threshold, wherein: The control action includes sending a warning notification to the receiving device.

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