Battery Circuit Board Trace Loops for Electrolyte Leak Detection

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Solution Overview

Problem

Existing batteries lack reliable and cost-effective mechanisms to detect electrolyte leaks, which can cause short circuits and reduce capacity, and current solutions are bulky, affecting volumetric energy density.

Innovation Solution

A circuit board design with closely spaced closed loops and an electrical assembly to detect electrolyte presence through voltage differences, using resistors to manage short circuits and alert the battery management unit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional electrolyte leak detection features are used, then detection capability is provided, but the device becomes large and expensive

Engineering Contradiction:

Improveelectrolyte leak detection capabilityVSAvoidsize and cost of detection features

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical or electronic sensor systems with a simple electrical conductivity detection method using trace circuits on the circuit board. The detection is achieved through electrical measurements rather than mechanical sensors, reducing device complexity while maintaining detection capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses the circuit board's existing trace structures as detection elements, effectively copying the board's own electrical pathways for dual purposes: normal circuit operation and electrolyte leak detection. This eliminates the need for separate detection components.

Inventive Principle:

Principle #26Copying

2Reliability

If traditional electrolyte leak detection features are used, then detection capability is provided, but volumetric energy density is reduced

Engineering Contradiction:

Improveelectrolyte leak detection capabilityVSAvoidvolumetric energy density

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The trace circuits on the circuit board serve multiple functions: normal electrical connectivity for battery management and electrolyte leak detection. By making the detection system multi-functional rather than dedicated, no additional space-consuming components are required.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the electrolyte leak detection function with the existing circuit board trace structures. The same electrical pathways used for normal operation are also used for detection, combining two functions into one integrated system that occupies no additional volume.

Inventive Principle:

Principle #5Merging (Combining)

3Measurement precision

If closely spaced trace circuits are used for detection, then detection sensitivity is improved, but short circuit risk increases

Engineering Contradiction:

Improveelectrolyte leak detection sensitivityVSAvoidshort circuit risk

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces electrical insulation as an intermediary between closely spaced trace circuits. The insulating layer prevents direct electrical contact between traces while allowing electrolyte to bridge the gap and create detectable conductivity changes, thus enabling sensitive detection without direct short circuits.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the electrical state parameters by applying voltage to specific trace circuits and measuring conductivity changes. By controlling voltage application and measuring electrical properties rather than relying on physical contact, the system achieves sensitive detection while managing short circuit risks through electrical control.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Provides small, reliable, and cost-effective electrolyte leak detection, preventing short circuits and enabling controlled battery responses to leaks.

Implementation Method 1

a first closed loop trace and a second closed loop trace, spaced apart from one another and configured to detect a presence of an electrolyte on the circuit board through electrochemical migration

Methodology Applied

Scientific EffectElectrochemical migration:

Data Source

PatentUS12431546B2Detecting electrolyte on circuit boards

Publication Date: 2025.09.30 APPLE INC

AI summary

A battery circuit board includes a substrate, a first trace configured to receive a voltage and forming a first closed loop around a perimeter of the substrate, and a second trace forming a second closed loop around the perimeter of the substrate. The battery circuit board also includes an electrical assembly configured to determine a presence of an electrolyte on the battery circuit board in response to a short circuit between the first closed loop of the first trace and the second closed loop of the second trace.