System and method for differentiating between exhaust and leakage conditions in battery pack

Abstract

A system for differentiating between an exhaust condition and a leak condition of an electrolyte vapor released from a battery pack is disclosed. The system includes: a sensing element having a polymeric support for detecting a concentration of electrolyte vapor; a heating element positioned and configured to heat the polymeric support of the sensing element to vaporize the electrolyte from the polymeric support; at least one processor communicatively coupled with the sensing element and the heating element to enable and then disable the heating element for an amount of time; determining an exhaust condition when the concentration of the electrolyte vapor exceeds a threshold level within a predefined time interval after the heating element is deactivated; a leak condition is determined when the concentration of the electrolyte vapor does not exceed a threshold level within a predefined time interval.

Description

Technical Field

[0001] The exemplary embodiments disclosed herein relate generally to a system for a battery pack, and more specifically to a system and method for distinguishing between venting and leakage conditions of electrolyte vapors released from the battery pack. Background Technology

[0002] In battery packs such as lithium-ion battery packs, trace amounts of electrolyte vapor are sometimes released due to leakage and / or venting. During venting conditions within the battery pack, a higher concentration of electrolyte vapor is released than during leakage conditions. However, conventional sensors struggle to distinguish between leakage and venting conditions within the battery pack.

[0003] The inventors have identified numerous areas for improvement in the prior art and methods, which are the subject of the embodiments described herein. Through effort, ingenuity, and innovation, many of these deficiencies, challenges, and problems have been addressed by developing solutions included in the embodiments of this disclosure, some examples of which are described in detail herein. Summary of the Invention

[0004] The following is a simplified overview to provide a basic understanding of some aspects of this disclosure. This invention is not an exhaustive summary and is neither intended to identify key or essential elements nor to describe a range of such elements. Its purpose is to provide, in a simplified form, some concepts of the described features as a prelude to the more detailed description provided later.

[0005] In an example embodiment, a system for distinguishing between venting and leakage conditions of electrolyte vapor released from a battery pack is disclosed. The system includes a sensing element configured to detect the concentration of electrolyte vapor released from the battery pack. Furthermore, the sensing element includes a polymer support. The system also includes a heating element positioned and configured to heat the polymer support of the sensing element to evaporate electrolyte from the polymer support; and at least one processor communicatively coupled to the sensing element and the heating element. Additionally, the at least one processor is configured to activate the heating element for a duration of time and then deactivate it, determining a venting condition if the concentration of electrolyte vapor exceeds a threshold level within a predefined time interval after the heating element is deactivated, and determining a leakage condition if the concentration of electrolyte vapor does not exceed a threshold level within the predefined time interval.

[0006] In some embodiments, at least one processor is configured to trigger an alarm via an alarm unit communicatively coupled to the at least one processor upon determining an exhaust condition. In some embodiments, the concentration of electrolyte vapor increases rapidly during an exhaust condition compared to the concentration of electrolyte vapor during a leakage condition.

[0007] In some implementations, at least one processor is further configured to iteratively enable the heating element for a specified time period and then deactivate the heating element for a second specified time period. Furthermore, the second specified time period is less than or equal to a predefined time interval to prevent the concentration of electrolyte vapor from exceeding a threshold level and to prevent an alarm from being triggered by an alarm unit in the event of a leakage of electrolyte vapor released from the battery pack.

[0008] In some embodiments, the heating element is activated by at least one processor for a sufficient amount of time to evaporate the electrolyte from the polymer support of the sensing element. In some embodiments, the heating element is configured to raise the temperature of the polymer support of the sensing element to a set temperature sufficient to evaporate the electrolyte from the polymer support of the sensing element.

[0009] In some embodiments, the polymer support is positioned and configured to absorb electrolyte vapor released from the battery pack. In some embodiments, the heating element includes a microelectromechanical system (MEMS) heater. In some embodiments, the heating element is positioned to heat the polymer support by locally positioning it to, contacting, being coplanar with, or below the sensing element. In some embodiments, a predefined time interval is greater than five minutes.

[0010] In another example embodiment, a method is disclosed. The method includes the steps of: detecting the concentration of electrolyte vapor released from a battery pack via a sensing element, wherein the sensing element includes a polymer support; heating the polymer support via a heating element positioned together with the polymer support of the sensing element to evaporate electrolyte from the polymer support; enabling the heating element for a duration of time via at least one processor communicatively coupled to the sensing element and the heating element and then deactivating the heating element; determining an venting condition via at least one processor, wherein the concentration of electrolyte vapor exceeds a threshold level within a predefined time interval after the heating element is deactivated; and determining a leakage condition via at least one processor if the concentration of electrolyte vapor does not exceed the threshold level within the predefined time interval.

[0011] The above description of the invention is provided merely to outline some exemplary embodiments to provide a basic understanding of some aspects of the invention. Therefore, it should be understood that the above embodiments are merely illustrative and should not be construed as limiting the scope or nature of the invention in any way. It should be understood that, in addition to those described herein, the scope of the invention covers many possible embodiments, some of which will be further described below. Attached Figure Description

[0012] Therefore, some exemplary embodiments of this disclosure have been described in general terms, and reference will be made below to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0013] Figure 1 A block diagram illustrating a system for distinguishing between venting and leakage conditions of electrolyte vapors released from a battery pack, according to an example embodiment of the present disclosure;

[0014] Figure 2A A schematic diagram illustrating a sensing element in a leakage condition according to an example embodiment of the present disclosure is shown;

[0015] Figure 2B A schematic diagram illustrating a sensing element in an exhaust condition according to an example embodiment of the present disclosure is shown;

[0016] Figure 3A A graph illustrating the change of the corresponding signal of the sensing element according to an example embodiment of the present disclosure is shown, as well as another graph illustrating the triggering of an alarm during a leakage condition;

[0017] Figure 3B A graph illustrating the change of the corresponding signal of the sensing element according to an example embodiment of the present disclosure is shown, as well as another graph illustrating the triggering of an alarm during exhaust conditions;

[0018] Figure 4 A schematic diagram illustrating the operation of a system according to an example embodiment of this disclosure is shown;

[0019] Figure 5A A graphical representation of the operation of the system during exhaust conditions according to an example embodiment of the present disclosure is illustrated;

[0020] Figure 5B A graphical representation of the operation of the system during a leakage condition is illustrated according to an example embodiment of the present disclosure;

[0021] Figure 6 A graphical representation of a system under leakage conditions according to an example embodiment of the present disclosure is illustrated; and

[0022] Figure 7A flowchart illustrating a method for distinguishing between venting and leakage conditions of electrolyte vapors released from a battery pack, according to an example embodiment of the present disclosure, is provided. Detailed Implementation

[0023] Some embodiments will now be described more fully below with reference to the accompanying drawings, which illustrate some embodiments, but not all embodiments. In fact, various embodiments can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will meet applicable legal requirements.

[0024] The components illustrated in the accompanying drawings represent components that may or may not be present in the various embodiments of the invention described herein, such that embodiments may include fewer or more components than those shown in the figures without departing from the scope of the invention. Some components may be omitted from one or more figures, or shown in dashed lines to make the components below visible.

[0025] As used herein, the term “comprising” means including but not limited to, and should be interpreted in the manner in which it is typically used in the patent context. The use of broader terms such as “comprising,” “including,” and “having” should be understood to provide support for narrower terms such as “consisting of,” “substantially composed of,” and “substantially constituted by.”

[0026] The phrases “in various embodiments,” “in one embodiment,” “according to one embodiment,” “in some embodiments,” etc., generally mean that the specific feature, structure, or characteristic following the phrase may be included in at least one embodiment of this disclosure, and may be included in more than one embodiment of this disclosure (importantly, such phrases do not necessarily refer to the same embodiment).

[0027] As used herein, the terms “example” or “exemplary” mean “serving as an example, instance, or illustration.” Any specific implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other specific implementations.

[0028] If this specification states that a component or feature is "may", "can", "may", "should", "will", "preferably", "possibly", "usually", "optionally", "for example", "often", or "maybe" (or other such language) included or has a characteristic, then the specific component or feature does not need to be included or have that characteristic. Such components or features may be optionally included in some embodiments or may be excluded.

[0029] This disclosure provides various embodiments of a system for distinguishing between venting and leakage conditions of electrolyte vapor released from a battery pack. The system may include a sensing element, a polymer support, a heating element, and at least one processor. Embodiments may be configured to detect the concentration of electrolyte vapor released from the battery pack. Embodiments may be configured to evaporate electrolyte from the polymer support. Embodiments may be configured to determine whether the electrolyte vapor released from the battery pack is venting or leakage.

[0030] Figure 1 A block diagram of a system 100 for distinguishing between venting and leakage conditions of electrolyte vapors released from a battery pack, according to an example embodiment of the present disclosure, is illustrated. Figure 2A A schematic diagram of a sensing element 102 in a leakage condition according to an example embodiment of the present disclosure is illustrated. Figure 2B A schematic diagram of a sensing element 102 in an exhaust condition according to an example embodiment of the present disclosure is shown.

[0031] In some embodiments, system 100 includes a sensing element 102 configured to detect the concentration of electrolyte (e.g., during leakage or venting conditions in the battery pack). Figure 2A and Figure 2B (As shown). In some embodiments, a battery pack leakage condition corresponds to the leakage of electrolyte from the battery cells of the battery pack in the form of electrolyte vapor 200 due to manufacturing defects or degradation over time. In some embodiments, a battery pack venting condition corresponds to the release of electrolyte in the form of electrolyte vapor 200 due to internal pressure buildup within the battery pack. In the example, a venting condition may release more electrolyte vapor from the battery pack compared to a leakage condition. In some embodiments, during a leakage condition, electrolyte vapor 200 gradually accumulates inside the battery pack, while during a venting condition, electrolyte vapor 200 rapidly accumulates inside the battery pack. In some embodiments, system 100 may be installed within the battery pack to detect the release of electrolyte vapor 200 during either a leakage or venting condition. In some embodiments, system 100 may include a sensing element 102, a heating element 106, and at least one processor 108. The sensing element may include a polymer support 104. System 100 may include an alarm unit 110. In various examples, the sensing element is configured to be the same as or similar to the sensor described in U.S. Patent Application No. 18 / 164,314, filed February 3, 2023 and published as U.S. Patent No. 2024 / 0264106A1, which is hereby incorporated herein by reference in its entirety.

[0032] In some embodiments, the sensing element 102 may be included on the substrate 202 (e.g., Figure 2AThe polymer support 104 is positioned above the substrate 202 (shown in the diagram). The polymer support 104 can interact with (e.g., absorb) electrolyte vapor 200 during leakage or venting conditions. In some embodiments, the substrate 202 may provide the structural basis for the polymer support 104. In some embodiments, the polymer support 104 may be uniformly coated over the substrate 202. In an example, the polymer support 104 may be doped with an ionic salt. Furthermore, the ionic salt can facilitate the movement of ions within the matrix of the polymer support 104. When the polymer support 104 comes into contact with an analyte, the movement of ions within the matrix increases the conductivity of the polymer support 104. In some embodiments, the analyte corresponds to a fluid-like chemical component that interacts with the polymer support 104. In the examples herein, the analyte may be an electrolyte that serves as a fluid within the battery pack.

[0033] In some embodiments, the polymer support 104 may be configured to absorb at least some of the electrolyte vapor 200. For example, the polymer support 104 may absorb some of the electrolyte vapor 200 when it is present in the sensing element 102. In some embodiments, absorbing at least some of the electrolyte vapor 200 may solubilize the polymer support 104. In this respect, for example, the polymer support 104 may become more flexible. In some embodiments, the polymer support 104 may include an ionic salt. In some embodiments, absorbing at least some of the electrolyte vapor 200 may solubilize the ionic salt. In this respect, for example, the ionic salt may dissolve into the polymer support 104 (e.g., the ionic salt may dissociate into ions). In some embodiments, the polymer support 104 may absorb some of the electrolyte vapor 200 (and solubilize the polymer support 104 and / or the ionic salt) within one minute of being in the electrolyte vapor 200, in the presence of the sensing element 102. In some embodiments, at least some electrolyte vapor 200 is absorbed, thus causing solvation of the polymer support 104 and / or ionic salt, resulting in an increase in the conductivity of the polymer support 104. In this respect, for example, if the conductivity of the polymer support 104 increases, the impedance of the polymer support 104 may decrease. As another example, if the conductivity of the polymer support 104 increases, the phase angle associated with the polymer support 104 (e.g., the phase angle of the impedance of the polymer support 104) may be shifted (e.g., the phase angle associated with the polymer support 104 may be shifted such that the phase angle exceeds a phase angle threshold).

[0034] In some embodiments, electrolyte vapor 200 can be any vapor capable of solvating ionic salts. For example, as described above, electrolyte vapor 200 may be associated with one or more battery packs. In some embodiments, electrolyte vapor 200 may be released from one of the battery packs. In some embodiments, electrolyte vapor 200 may consist of one or more of the following: propylene glycol carbonate (PC), ethylene carbonate (EC), diethyl carbonate (DEC), dimethyl carbonate (DMC), ethyl methyl carbonate (EMC), dimethoxyethane (DME), or γ-butyrolactone (GBL).

[0035] In some embodiments, during a leakage condition, electrolyte vapor 200 gradually accumulates inside the battery pack. In some embodiments, the rate of change of electrolyte vapor 200 concentration during a leakage condition may be slower or relatively slower than under a venting condition. Therefore, in this example, the concentration of electrolyte vapor 200 may be sufficiently increased to interact with the polymer support 104 over a longer time interval. Furthermore, because the concentration of electrolyte vapor 200 increases sufficiently over a longer time interval, the polymer support 104 may become saturated.

[0036] In some embodiments, during venting conditions, electrolyte vapor 200 rapidly accumulates inside the battery pack. In some embodiments, the rate of change of electrolyte vapor 200 concentration during venting conditions may be faster or relatively faster than under leakage conditions. Therefore, in this example, the concentration of electrolyte vapor 200 can be sufficiently increased to interact with the polymer support 104 within a shorter time interval. Furthermore, because the concentration of electrolyte vapor 200 increases sufficiently within a shorter time interval, the polymer support 104 may become saturated.

[0037] In the example, during a leakage condition, the concentration of electrolyte vapor 200 can be sufficiently increased to interact with the polymer support 104 within a time interval "T" (as depicted in 204), while during a venting condition, the concentration of electrolyte vapor 200 can be sufficiently increased to interact with the polymer support 104 within a time interval "t" (as depicted in 206). In some embodiments, the time interval "T" can be greater than the time interval "t". In the example, the time interval "T" can range from 5 minutes to several hours or days, and the time interval "t" can range from a few seconds to at most one minute. In the example, during a leakage condition, the concentration of electrolyte vapor 200 can be sufficiently increased to interact with the polymer support 104 within a time interval "T". In some embodiments, during a venting condition, the concentration of electrolyte vapor 200 can be sufficiently increased to interact with the polymer support 104 within a time interval "t". Therefore, in some embodiments, the sensing element 102 can generate a corresponding signal within the time interval "T" during a leakage condition. In addition, the sensing element 102 can generate a corresponding signal within a time interval "t" during a leakage condition.

[0038] In some embodiments, heating element 106 may be coupled to sensing element 102. Heating element 106 may heat polymer support 104 of sensing element 102 to evaporate electrolyte from polymer support 104. In some embodiments, heating element 106 may raise the temperature of sensing element 102 to a predefined temperature, which may be greater than ambient temperature and sufficient to evaporate electrolyte from polymer support 104. In some embodiments, the predefined temperature may be in the range of 50°C to 150°C. In some embodiments, the predefined temperature may depend on polymer support 104 or electrolyte. In some embodiments, heating element 106 may correspond to microelectromechanical system (MEMS) heating element. In an example, microfabrication techniques may be used to fabricate a MEMS heating element in contact with substrate 202 of sensing element 102. MEMS heating element may include a silicon substrate having microscale resistive elements that generate heat in response to electrical stimulation. Furthermore, in some embodiments, the heating element 106 can be coupled to the sensing element 102 by positioning the heating element 106 at least partially coplanar with or below the sensing element.

[0039] In the example, heating element 106 may be positioned near polymer support 104 via substrate 202, such as below polymer support. In some embodiments, at least one processor 108 may enable heating element 106 for a certain amount of time to evaporate electrolyte and reset the corresponding signal to a baseline signal. In some embodiments, at least one processor 108 may enable heating element 106 until the corresponding signal 310 (shown in FIG. 3) of sensing element 102 stabilizes (e.g., within 1% of the maximum value of corresponding signal 310). In the example, at least one processor 108 may enable heating element 106 until the corresponding signal 310 (shown in FIG. 3) of sensing element 102 is reset. In some embodiments, the baseline signal may correspond to a zero or empty corresponding signal from sensing element 102. In some embodiments, the baseline signal may correspond to a sufficient amount of electrolyte concentration evaporated from sensing element, which may be below a threshold level 308. For example, the baseline signal may correspond to less than 10% saturation of electrolyte in the polymer support of sensing element. An increase in temperature of the sensing element 102 can cause the electrolyte absorbed on the sensing element 102 to evaporate. Due to the evaporation of the electrolyte, the sensing element 102 resets, causing the corresponding signal to reset at most to the baseline signal. In some embodiments, the baseline signal is below a threshold level.

[0040] In some embodiments, at least one processor 108 may subsequently deactivate the heating element 106 to record changes in the corresponding signal over one or more time amounts or time intervals following the deactivation of the heating element 106. In some embodiments, at least one processor 108 may analyze changes in the corresponding signal relative to a threshold level. In some embodiments, the system 100 may further include an alarm unit 110 coupled to at least one processor 108. The alarm unit 110 may be configured to generate an alarm when the corresponding signal from the sensing element 102 exceeds a threshold level. In some embodiments, the threshold level may be half or a quarter of the corresponding signal generated by the sensing element 102. In some embodiments, at least one processor 108 may be configured to trigger an alarm via the alarm unit 110 when the corresponding signal exceeds the threshold level. In some embodiments, at least one processor 108 is configured to trigger an alarm via the alarm unit 110 upon determining the exhaust condition.

[0041] In some embodiments, during venting conditions, the electrolyte rapidly accumulates inside the battery pack in the form of electrolyte vapor 200. In some embodiments, the rate of increase in electrolyte concentration in the battery pack during venting conditions may be faster or relatively faster than during leakage conditions. Therefore, in this example, the electrolyte concentration can be detected by sensing element 102, and a corresponding signal may exceed a threshold level within a predefined time interval (e.g., a shorter time interval). In some embodiments, sensing element 102 may generate a corresponding signal that may exceed a threshold level within a time interval "T" during leakage conditions. Furthermore, sensing element 102 may generate a corresponding signal that may exceed a threshold level within a time interval "t" during venting conditions.

[0042] In some embodiments, during a leakage condition, electrolyte vapor 200 may gradually accumulate inside the battery pack. In some embodiments, during a leakage condition, the rate of increase in the concentration of electrolyte vapor 200 in the battery pack may be slower or relatively slower than under a venting condition. Therefore, in the example, the concentration of electrolyte vapor 200 may be detected by sensing element 102, and the corresponding signal may exceed a threshold level over a longer time interval. In some embodiments, at least one processor 108 may be configured to iteratively enable heating element 106 for a certain amount of time and then deactivate heating element 106 for a second amount of time. The second amount of time is less than or equal to a predefined time interval to prevent the concentration of electrolyte vapor 200 from exceeding a threshold level. Furthermore, the second amount of time is less than or equal to a predefined time interval to prevent an alarm from being triggered by alarm unit 110 when a leakage condition occurs with electrolyte vapor 200 released from the battery pack. Additionally, at least one processor 108 may distinguish between a venting condition and a leakage condition by triggering an alarm within a time interval "t" for a venting condition and a time interval "T" for a leakage condition, such that "T" is relatively greater than "t".

[0043] Figure 3A A graph 300 illustrating the change of the corresponding signal of the sensing element 102 according to an example embodiment of the present disclosure is shown, as well as another graph 302 illustrating the triggering of an alarm during a leakage condition. Figure 3B Graph 324, illustrating the change of the corresponding signal of the sensing element 102 according to an example embodiment of the present disclosure, and graph 326, illustrating the triggering of an alarm during exhaust conditions, are illustrated.

[0044] In the example, such as Figure 3AAs shown, the change of the corresponding signal 310 with respect to time during a leakage condition can be plotted as a graph 300. This graph 300 includes an X-axis 304 and a Y-axis 306. The X-axis 304 represents time, and the Y-axis 306 represents the change of the corresponding signal 310. The graph 300 also includes a threshold level 308. The threshold level 308 can be considered as 50% of the maximum value of the corresponding signal 310 at its maximum value (312 is shown as 50% of the maximum value of the corresponding signal 310). In this example, the threshold level 308 can be in the range of 25% to 90% of the maximum value of the corresponding signal 310. In this example, the maximum value of the corresponding signal 310 can correspond to the saturation of the polymer support 104 when interacting with extremely high concentrations of electrolyte vapor 200.

[0045] In the example, when the heating element 106 is deactivated, the corresponding signal 310 (e.g., electrolyte concentration) may increase. In some embodiments, the corresponding signal 310 may exceed a threshold level 308 at a time interval 314. Furthermore, the rate of change of the corresponding signal 310 may be low. Additionally, due to the low rate of change of the corresponding signal 310, the time interval 314 during which the corresponding signal 310 exceeds the threshold level 308 may be relatively longer (compared to venting conditions). In some embodiments, the low rate of change of the corresponding signal 310 corresponds to a leakage condition in the battery pack. Furthermore, during a leakage condition, the corresponding signal 310 may gradually increase and exceed the threshold level 308 within a time interval 314(T).

[0046] In the example shown in graph 302, time is plotted on the X-axis 316, and the alarm output 320 of sensing element 102 is plotted on the Y-axis 318. Graph 302 is linked to graph 300 within time interval 314 (specifically at time 322), where an alarm is activated when the concentration of electrolyte vapor 200 exceeds a threshold level 308 (e.g., Figure 3A (As shown). In the example, at least one processor 108 may trigger alarm unit 110, as shown in alarm output 320. As shown in graph 302, before time interval 314, at least one processor 108 may not trigger alarm unit 110 because the corresponding signal 310 is below threshold limit 308. Furthermore, after time interval 314, at time 322, at least one processor 108 may trigger alarm unit 110 (shown as alarm output 320) when the corresponding signal 310 exceeds threshold level 308. In some embodiments, at least one processor 108 may trigger alarm unit 110 after time interval 314, which may range from up to 5 minutes to several hours or days (“T”) during the leakage condition.

[0047] In the example, such as Figure 3BAs shown, the change in the corresponding signal 332 caused by the change in the concentration of electrolyte vapor 200 relative to time during exhaust conditions can be plotted as a curve 324. This curve 324 includes an X-axis 328 and a Y-axis 330. The X-axis 328 represents time, and the Y-axis 330 represents the change in the corresponding signal 332 from the sensing element 102. The curve 324 also includes a threshold level 308. Similar to... Figure 3A Threshold level 308 can be considered as 50% of the maximum value of the corresponding signal (334 is shown as 50% of the maximum value). In the example, the maximum value of the corresponding signal 332 can be correlated with the saturation of the polymer support 104 interacting with a very high concentration of electrolyte vapor 200 under exhaust conditions.

[0048] In some embodiments, the corresponding signal 332 may exceed the threshold level 308 within a time interval 336. Furthermore, the rate of change of the corresponding signal 332 may be high. Additionally, due to the high rate of change of the corresponding signal 332, the time interval 336 during which the corresponding signal 332 exceeds the threshold level 308 may be smaller. In some embodiments, the high rate of change of the corresponding signal 332 corresponds to the venting condition in the battery pack. Furthermore, during the venting condition, the corresponding signal 332 may increase and exceed the threshold level 308 within a time interval 336, which may range from a few seconds to a minute ("t") compared to the range of 5 minutes to several hours or days ("T") under a leakage condition.

[0049] In the example shown in graph 326, time is plotted on the X-axis 338, and the triggering of alarm unit 110 in the form of alarm output 342 is plotted on the Y-axis 340. Graph 326 links to graph 324 within time interval 336. As shown in graph 326, before time interval 336, at least one processor 108 may not trigger an alarm because the corresponding signal 332 is below the threshold limit 308. Furthermore, after time interval 314, at least one processor 108 may trigger alarm unit 110 (shown as alarm output 342) when the corresponding signal 332 exceeds the threshold level 308. In some embodiments, at least one processor 108 may trigger alarm unit 110 after time interval 336, which may be in the range of a few seconds to a minute ("t") compared to the range of 5 minutes to several hours or days ("T") in a leakage condition.

[0050] Figure 4 A schematic diagram 400 illustrates the operation of system 100 according to an example embodiment of the present disclosure. Figure 5A A graphical representation of the operation of system 100 during exhaust conditions is illustrated according to an example embodiment of the present disclosure. Figure 5BA graphical representation of the operation of system 100 during a leakage condition is illustrated according to an example embodiment of the present disclosure.

[0051] In some embodiments, system 100 includes a sensing element 102. This sensing element 102 can detect the concentration of electrolyte vapor 200 during leakage or venting conditions in the battery pack and generate a corresponding signal 508 (e.g., Figures 5A to 5B (As shown). In some embodiments, the sensing element 102 may include a polymer support 104. The polymer support 104 may interact with the electrolyte vapor 200 and generate a corresponding signal 508. The corresponding signal 508 may be recorded and analyzed by at least one processor 108.

[0052] In some embodiments, system 100 may include an alarm unit 110. Alarm unit 110 may generate an alarm when a corresponding signal 508 exceeds a threshold level 308. In some embodiments, the threshold level 308 may be at least 25% of 50% of the maximum value of the corresponding signal 508. In some embodiments, the maximum value of the corresponding signal 508 may correspond to the polymer support 104 being saturated with electrolyte vapor 200.

[0053] In the example, such as Figure 5A and Figure 5BAs shown, graph 502 plots the change of the corresponding signal 508 (e.g., a signal indicating electrolyte concentration) relative to time. Graph 502 includes an X-axis 504 and a Y-axis 506. The X-axis 504 may represent time, and the Y-axis 506 may represent the change of the corresponding signal 508 (e.g., a signal indicating electrolyte concentration) from the sensing element 102. Graph 502 also includes a threshold level 308. In the example, the change of the corresponding signal 508 may be constant when the heating element 106 remains off. In the example, when the corresponding signal 508 exceeds the threshold level 308, at least one processor 108 may trigger an alarm unit 110. In some embodiments, as shown in graph 502, in scenarios where the heating element 106 is "off" and the corresponding signal 508 has exceeded the threshold level 308, the alarm may be "on" during venting conditions and during leakage conditions (shown as alarm output 516 in graph 510). Therefore, when the heating element 106 is "off" before being "on", the system may be unable to distinguish between venting and leakage conditions, as the alarm can be "on" in both conditions. In the example, the polymer support 104 can interact with (e.g., absorb) the electrolyte vapor 200 present in the battery pack. Furthermore, the polymer support 104 of the sensing element 102 can interact with the electrolyte vapor 200, and thus the sensing element 102 can generate a corresponding signal 508 indicating the electrolyte concentration in the polymer support 104 of the sensing element 102. When the corresponding signal 508 exceeds a threshold level, at least one processor 108 can trigger an alarm in both leakage and venting conditions. In another example, the alarm can be "on" when the corresponding signal 508 exceeds a threshold level 308, and "off" when the corresponding signal 508 is less than or equal to the threshold level 308.

[0054] In some implementations, at least one processor 108 can analyze and process the corresponding signal 508 as an alarm output 516. In the example shown in graph 510, time is plotted on the X-axis 512, and alarm outputs "on" and "off" are plotted on the Y-axis 514. In the example, at least one processor 108 can trigger an alarm unit 110, shown as alarm output 516. As shown in graph 510, at least one processor 108 can trigger alarm unit 110 (shown as alarm output 516 on) upon receiving the corresponding signal 508.

[0055] In some embodiments, system 100 may include a heating element 106 coupled to sensing element 102. At least one processor 108 may enable heating element 106 for a duration to raise the temperature of sensing element 102. In some embodiments, heating element 106 may correspond to a microelectromechanical system (MEMS) heating element. In some embodiments, at least one processor 108 may enable heating element 106 to reset corresponding signal 508 to a baseline signal. In some embodiments, the baseline signal may correspond to corresponding signal 508 from sensing element 102 that is zero, empty, or below a threshold level 308.

[0056] In the example, at least one processor 108 can enable the heating element 106 (represented as...). Figure 4 Arrow 402) reaches a time quantity. For example... Figure 5A As shown, the change of the corresponding signal 508 with respect to time is plotted in graph 502. Graph 502 also includes a threshold level 308. In the example, when the heating element 106 is activated for a certain amount of time, the corresponding signal 508 (e.g., a signal indicating electrolyte concentration) may decrease to reset to the baseline signal. In the example, the corresponding signal 508 may decrease to reset to the baseline signal due to the evaporation of electrolyte vapor 200 absorbed on the sensing element 102.

[0057] In the example, when the heating element 106 is activated (represented as...) Figure 4 When arrow 402 is shown, when the corresponding signal 508 is below the threshold level 308, at least one processor 108 may stop triggering an alarm via alarm unit 110, as shown in alarm output 516. As shown in graph 510, due to the corresponding signal 508, at least one processor 108 may stop triggering an alarm via alarm unit 110 (shown as alarm output 516 is off).

[0058] In some implementations, the heating element 106 can then be deactivated at predefined time intervals (represented as...). Figure 4 Arrow 404). Following arrow 406 for exhaust conditions and arrow 408 for leakage conditions, the result of deactivating the heating element 106 on the sensing element 102 and reabsorbing electrolyte vapor 200 is schematically shown (e.g.). Figure 4 (As shown). During venting conditions, electrolyte vapor 200 can rapidly saturate sensing element 102 above a threshold level 308 (e.g., time "t"). During leakage conditions, electrolyte vapor 200 can gradually saturate sensing element 102 above a threshold level 308 (e.g., time "T").

[0059] Furthermore, when the heating element 106 is deactivated, and after the corresponding signal 508 (due to the reabsorption of electrolyte vapor 200 on the sensing element 102) subsequently exceeds a threshold level 308, at least one processor 108 may be configured to trigger an alarm. At least one processor 108 may trigger an alarm via an alarm unit during exhaust conditions based at least on the change in the corresponding signal 508 relative to a baseline signal and / or the corresponding signal 508 exceeding the threshold level 308. In some embodiments, at least one processor 108 is configured to distinguish between exhaust conditions and leakage conditions by determining the time taken for the corresponding signal 508 to exceed the threshold level 308 after the heating element is “disconnected.”

[0060] In some implementations, at least one processor 108 is configured to enable for a duration of time and subsequently deactivate the heating element 106 for a second duration of time, as referenced. Figure 6 Further explanation. In some embodiments, the second time duration may be less than or equal to this time duration. In some embodiments, when the heating element 106 is enabled, the temperature rise of the sensing element 102 causes the electrolyte vapor 200 absorbed on the sensing element 102 to evaporate, which resets the corresponding signal 508 to the baseline signal. In the example, when the heating element 106 is enabled, the corresponding signal 508 may be at a time interval 518 (in Figure 5B As shown in graph 502 (after arrow 402), it decreases to below threshold level 308. In the example, when heating element 106 is deactivated, sensing element 102 can again absorb electrolyte vapor 200.

[0061] In some embodiments, during venting conditions (shown as 406), the rate of change in the concentration of electrolyte vapor 200 can be faster or relatively faster compared to leakage conditions. Therefore, high concentrations of electrolyte vapor 200 can be absorbed by the polymer support 104 of the sensing element 102. In some embodiments, during venting conditions, electrolyte vapor 200 can rapidly accumulate inside the battery pack. In some embodiments, during venting conditions, the rate of increase in the concentration of electrolyte vapor 200 in the battery pack can be faster than under venting conditions. Therefore, during venting conditions, high concentrations of electrolyte vapor 200 can be absorbed by the polymer support 104 of the sensing element 102.

[0062] like Figure 5AAs shown, during exhaust conditions (shown as 406), when the heating element 106 is deactivated at time intervals as indicated by “B”, the corresponding signal 508 (e.g., a signal indicating electrolyte concentration) can increase. The corresponding signal 508 can increase up to near a threshold level 308 and can exceed the threshold level 308 again after time interval 520. In this example, the corresponding signal 508 can increase rapidly due to the reabsorption of electrolyte vapor 200 on the sensing element 102. Furthermore, the high rate of change of the corresponding signal 508 relative to the baseline signal when the heating element 106 is deactivated corresponds to the exhaust conditions. Moreover, the rapid increase of the corresponding signal 508 and its exceeding of the threshold level 308 causes the alarm unit 110 to activate the alarm at time interval 520 (in… Figure 5A The alarm is triggered within the curve (shown in graph 510), indicating the exhaust status.

[0063] In some implementations, in leakage conditions (such as...) Figure 4 During the period indicated by arrow 408, electrolyte vapor 200 may gradually accumulate inside the battery pack. In some embodiments, the rate of change in the concentration of electrolyte vapor 200 during leakage conditions may be slower or relatively slower than during venting conditions. Figure 5B As shown, in leakage conditions (such as...) Figure 5B During the period indicated by arrow 408, when the heating element 106 is deactivated, the corresponding signal 508 may increase. The corresponding signal 508 may gradually increase up to near the threshold level 308, and during the time interval 522 (indicated by arrow 408), when the heating element 106 is deactivated, the corresponding signal 508 may increase. Figure 5B The time interval "T" shown may not exceed the threshold level 308, which is greater than the time interval 520 for exhaust conditions. Figure 5B (This is shown as "t"). In the example, due to the reabsorption of electrolyte vapor 200 on sensing element 102, the corresponding signal 508 can gradually increase. Furthermore, when heating element 106 is deactivated, the low rate of change of the corresponding signal 508 relative to the baseline signal corresponds to a leakage condition. Additionally, in a leakage condition, within time interval 520 (shown as "T"), the corresponding signal 508 gradually increases to approach the threshold level 308 without triggering an alarm (in...). Figure 5B The curve in graph 510 is shown as alarm output 516 being disconnected.

[0064] In some embodiments, at least one processor 108 can determine the exhaust condition (e.g., if the concentration of electrolyte vapor 200 exceeds a threshold level 308 within a predefined time interval after the heating element 106 is deactivated) when the concentration exceeds a threshold level 308. Figure 5A (As shown in graphs 500, 502, and 510). Furthermore, at least one processor 108 can determine the leakage condition if the concentration of the electrolyte vapor 200 does not exceed a threshold level within a predefined time interval (e.g., ...). Figure 5B(As shown in graphs 500, 502, and 510). Therefore, at least one processor 108 can trigger an alarm via alarm unit 110 upon determining the venting condition. The alarm can also be triggered in the event of a leak, but the time between alarm activations may be longer (e.g., time interval "T") compared to the venting condition (e.g., time interval "t").

[0065] Figure 6 A graphical representation of system 100 during a leakage condition is illustrated according to an example embodiment of the present disclosure.

[0066] In some embodiments, at least one processor 108 is configured to iteratively enable the heating element 106 for a specified time and then deactivate the heating element 106 for a second specified time. In some embodiments, the second specified time is less than or equal to a predefined time interval to prevent the concentration of electrolyte vapor 200 from exceeding a threshold level and to prevent an alarm from being triggered by alarm unit 110 during a leakage condition.

[0067] like Figure 6 As shown, graph 600 represents the on and off operation of heating element 106. Graph 602 represents the changes in corresponding signals 620 and 624 caused by changes in electrolyte concentration (shown as Y-axis 618) relative to time (shown as X-axis 616). Graph 604 represents the triggering of an alarm via alarm unit 110 in response to corresponding signals 620 and 624, where X-axis 628 shows the on / off operation of alarm unit 110 and Y-axis 626 shows time.

[0068] In some embodiments, when the heating element 106 can be activated by at least one processor 108 (shown as 606) during time interval 612, the concentration of the electrolyte can be reduced, as indicated by the corresponding signal 620 during time interval 622. Time intervals 612 and 622 can be equal and correspond to time amounts, wherein the corresponding signal 620 decreases from point "A" to point "B" while the heating element 106 remains activated. During time interval 620, an alarm can be triggered via alarm unit 110, as indicated by alarm output 630.

[0069] In some embodiments, during time intervals 608 and 610, when the heating element 106 is enabled, the corresponding signal 624 may increase. In some embodiments, at least one processor 108 may subsequently deactivate the heating element 106 for a second time duration 614. Therefore, the corresponding signal 624 may increase. The corresponding signal 624 may gradually increase up to near a threshold level 308 and may not exceed the threshold level 308 within the second time duration 614. In the example, the corresponding signal 624 may gradually increase due to the reabsorption of electrolyte vapor 200 on the sensing element 102. Furthermore, when the heating element 106 is deactivated, the low rate of change of the corresponding signal 624 relative to the baseline signal corresponds to a leakage condition. Furthermore, in a leakage condition, within the second time duration 614, the gradually increasing corresponding signal 624 approaches the threshold level 308 without triggering an alarm via the alarm unit 110 (shown as alarm output 632).

[0070] In some implementations, the second time amount 614 may be less than or equal to a predefined time interval to prevent the concentration of electrolyte vapor 200 from exceeding a threshold level. Furthermore, the second time amount 614, being less than or equal to the predefined time interval, prevents the alarm unit 110 from triggering an alarm in the event of a leak, thereby enabling the system 100 to distinguish between a leak and an venting condition. For example, in an venting condition, the corresponding signal 624 will increase rapidly and exceed the threshold level 309 before the heating element is subsequently “turned on.” In other words, time “t” (the amount of time it takes for the electrolyte level (corresponding signal 624) to exceed the threshold level 308 after the heating element is “turned off”) will be less than the second time amount 614 (the amount of time between the intermittent “turning on” of the heating element).

[0071] Figure 7 A flowchart illustrating a method 700 for distinguishing between venting and leakage conditions of electrolyte vapors released from a battery pack, according to an example embodiment of the present disclosure, is provided.

[0072] At operation 702, sensing element 102 can detect the concentration of electrolyte vapor 200 released from the battery pack. In some embodiments, sensing element 102 may be configured to detect the concentration of electrolyte vapor 200 (shown in FIG. 2). In some embodiments, sensing element 102 may include a polymer support 104 coated above substrate 202. In some embodiments, polymer support 104 may interact with electrolyte vapor 200 during leakage or venting conditions. In the example, the rate of change of the concentration of electrolyte vapor 200 may be different during leakage and venting conditions.

[0073] In some embodiments, the sensing element 102 can detect the concentration of electrolyte vapor 200 during leakage or venting conditions in the battery pack. In examples, the rate of change of the concentration of electrolyte vapor 200 can be different during leakage and venting conditions. In some embodiments, during leakage, electrolyte vapor 200 gradually accumulates inside the battery pack. In some embodiments, during leakage, the rate of change of the concentration of electrolyte vapor 200 can be slower or relatively slower than under venting conditions. Therefore, in examples, the concentration of electrolyte vapor 200 can be sufficiently increased to interact with the polymer support 104 over longer time intervals. In some embodiments, during venting, electrolyte vapor 200 rapidly accumulates inside the battery pack. In some embodiments, during venting, the rate of change of the concentration of electrolyte vapor 200 can be faster or relatively faster than under leakage conditions. Therefore, in examples, the concentration of electrolyte vapor 200 can be sufficiently increased to interact with the polymer support over shorter time intervals.

[0074] In some embodiments, the sensing element 102 may generate a corresponding signal 508 when the concentration of electrolyte vapor 200 is detected. Figures 5A to 5B (As shown in the example). In this example, the polymer support 104 of the sensing element 102 may be doped with an ionic salt. Furthermore, the ionic salt can promote the movement of ions within the matrix of the polymer support 104. When the polymer support 104 comes into contact with an analyte, the movement of ions within the matrix increases the conductivity of the polymer support 104. In some embodiments, the analyte corresponds to a chemical component that interacts with the polymer support 104. The chemical component interacting with the polymer support 104 can be measured or detected by the sensing element 102.

[0075] In the examples described herein, the analyte may be electrolyte vapor 200 in the battery pack. In some embodiments, when the electrolyte vapor 200 (analyte) interacts with the polymer support 104, the conductivity of the polymer support 104 may increase due to the movement of ions within the matrix of the polymer support 104. The increase in conductivity may be recorded and analyzed by at least one processor 108 to generate a corresponding signal 508. In some embodiments, the corresponding signal 508 may be proportional to the concentration of the electrolyte vapor 200 (analyte). Furthermore, the rate of change of the corresponding signal 508 may be proportional to the rate of change of the concentration of the electrolyte vapor 200.

[0076] At operation 704, the heating element 106, positioned together with the polymer support 104, can heat the polymer support 104 to evaporate the electrolyte from the polymer support 104. At operation 706, at least one processor 108 can enable the heating element 106 for a certain amount of time and then deactivate the heating element 106. In an example, at least one processor 108 may be configured to enable the heating element 106 for a certain amount of time to raise the temperature of the sensing element 102 and reset the corresponding signal 508 to a baseline signal. In some embodiments, the heating element 106 can raise the temperature of the sensing element 102 up to a predefined temperature above the ambient temperature. In some embodiments, the heating element 106 may correspond to a microelectromechanical system (MEMS) heating element. Furthermore, in some embodiments, the heating element 106 may be coupled to the sensing element 102 by positioning the heating element 106 at least partially coplanar with or below the sensing element. In an example, the temperature rise of the sensing element 102 may cause the electrolyte vapor 200 absorbed on the sensing element 102 to evaporate. As the absorbed signal evaporates, the sensing element 102 is reset, causing the corresponding signal 508 to be reset to at most the baseline signal.

[0077] In some embodiments, at least one processor 108 may subsequently deactivate the heating element 106 to subsequently record changes in the corresponding signal 508. In some embodiments, at least one processor 108 may analyze the corresponding signal 508 relative to at least a threshold level 308 (in... Figure 5A The text indicates the exhaust conditions and... Figure 5B The diagram shows changes in the leakage condition, baseline signal, and predefined time intervals. In some embodiments, when the heating element 106 is deactivated, the corresponding signal 508 shows a high rate of change relative to the baseline signal and the venting condition (shown in the diagram). Figure 5A Corresponding to (as shown in the diagram). In some embodiments, when the heating element 106 is deactivated, the low rate of change of the corresponding signal 508 relative to the baseline signal corresponds to leakage conditions in the battery pack (as shown in the diagram). Figure 5B (as shown in the image) corresponds to this.

[0078] At operation 708, at least one processor 108 can determine an venting condition in which the concentration of electrolyte vapor 200 exceeds a threshold level 308 within a predefined time interval after the heating element 106 is deactivated. Furthermore, at operation 710, at least one processor 108 can determine a leakage condition if the concentration of electrolyte vapor 200 does not exceed a threshold level within a predefined time interval. Additionally, at least one processor 108 can trigger an alarm via alarm unit 110 within a shorter time "t" during venting conditions, and within a relatively longer time "T" during leakage conditions.

[0079] In the example, when the heating element 106 is deactivated by at least one processor 108, the corresponding signal 508 can rapidly increase (due to the high rate of change of the corresponding signal) beyond the threshold level 308 that triggers an alarm within a predefined time interval under exhaust conditions.

[0080] In some embodiments, at least one processor 108 may enable the heating element 106 for a specified time and then deactivate the heating element 106 for a second specified time. In some embodiments, the second specified time is less than or equal to a predefined time interval, which prevents an alarm from being triggered by the alarm unit 110 in the event of a leakage condition of electrolyte vapor 200 released from the battery pack.

[0081] In the example, when heating element 106 is deactivated by at least one processor 108, the corresponding signal may gradually increase (due to the slow rate of change of the corresponding signal) up to near a threshold level (not exceeding the threshold level), which does not trigger an alarm within a predefined time interval under leakage conditions. Furthermore, since the second time amount is less than or equal to the (previous) time amount, the corresponding signal may not exceed the threshold level during subsequent activation and deactivation of the heating unit. Therefore, an alarm is triggered only during venting conditions.

[0082] The implementation can be configured to distinguish between leakage and venting conditions in the battery pack. The implementation can be configured to reset the sensing element 102 by activating the heating element 106. The implementation can be configured to record changes in the corresponding signal 508 of the sensing element 102 when the heating element 106 is subsequently activated and deactivated. The implementation can be configured to trigger an alarm within a time interval "t" during venting conditions and within a time interval "T" during leakage conditions, where "t" is less than "T".

[0083] Those skilled in the art to which this invention pertains will, upon benefiting from the teachings presented in the foregoing description and associated drawings, contemplate numerous modifications and other embodiments of the invention set forth herein. Therefore, it should be understood that the invention is not limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Furthermore, although the foregoing description and associated drawings have described exemplary embodiments in the context of certain example combinations of elements and / or functions, it should be understood that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, different combinations of elements and / or functions explicitly described above are also contemplated, as may be set forth in some of the appended claims. Although specific terms are used herein, they are used only in a general and descriptive sense and not for limiting purposes.

Claims

1. A system for distinguishing between venting and leakage conditions of electrolyte vapor released from a battery pack, the system comprising: A sensing element configured to detect the concentration of electrolyte vapor released from the battery pack, wherein the sensing element includes a polymer support; A heating element, positioned and configured to heat the polymer support of the sensing element to evaporate electrolyte from the polymer support; and At least one processor, the at least one processor being communicatively coupled to the sensing element and the heating element, wherein the at least one processor is configured to: The heating element is activated for a certain period of time and then deactivated. The exhaust condition is determined when the concentration of the electrolyte vapor exceeds a threshold level within a predefined time interval after the heating element is deactivated; and The leakage condition is determined if the concentration of the electrolyte vapor does not exceed the threshold level within the predefined time interval.

2. The system of claim 1, wherein the at least one processor is configured to trigger an alarm via an alarm unit communicatively coupled to the at least one processor upon determining the exhaust condition.

3. The system of claim 2, wherein the concentration of the electrolyte vapor increases rapidly during the venting condition compared to the concentration of the electrolyte vapor during the leakage condition.

4. The system of claim 2, wherein the at least one processor is configured to iteratively: The heating element is activated for the specified amount of time; and The heating element was then deactivated for a second period of time. The second time value is less than or equal to the predefined time interval to prevent the concentration of the electrolyte vapor from exceeding the threshold level and to prevent the alarm from being triggered by the alarm unit when there is a leakage of the electrolyte vapor released from the battery pack.

5. The system of claim 1, wherein the amount of time during which the heating element is activated by the at least one processor is sufficient to evaporate the electrolyte from the polymer support of the sensing element.

6. The system of claim 5, wherein the heating element is configured to raise the temperature of the polymer support of the sensing element to a set temperature sufficient to evaporate the electrolyte from the polymer support of the sensing element.

7. The system of claim 1, wherein the polymer support is positioned and configured to absorb the electrolyte vapor released from the battery pack.

8. The system of claim 1, wherein the heating element comprises a microelectromechanical system (MEMS) heater.

9. The system of claim 1, wherein the heating element is positioned to heat the polymer support by being partially positioned to the sensing element, in contact with the sensing element, coplanar with the sensing element, or below the sensing element.

10. The system of claim 1, wherein the predefined time interval is greater than five minutes.

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