Battery Cap Gas Sensor for Electrolyte Leakage Detection
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Solution Overview
Problem
Secondary batteries with electrolytes face challenges in detecting and preventing electrolyte leakage, which can lead to short circuits, overheating, and accidents due to inadequate sealing and overcharge, resulting in potential fires.
Innovation Solution
A battery pack equipped with a gas sensor to detect electrolyte leakage by monitoring vapor pressure or electrical changes, coupled with a protective circuit module that stops charge/discharge operations and forcibly discharges the battery upon leakage detection, ensuring safety and preventing accidents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gas sensor is added to detect electrolyte leakage, then battery safety is improved, but device complexity increases
Solution Approach 1:
The gas sensor is integrated with the protective circuit module, combining detection and protection functions into a single unit. This reduces the number of separate components and simplifies the overall device structure while maintaining improved safety through electrolyte leakage detection.
2Reliability
If a protective circuit module is added to stop charge/discharge operations upon leakage detection, then battery safety is improved, but device complexity increases
Solution Approach 1:
The protective circuit module is integrated with the gas sensor into a single combined unit. This merging of detection and protection functions reduces component count and simplifies device structure while ensuring battery safety through automated charge/discharge stopping upon electrolyte leakage detection.
3Measurement precision
If the gas sensor is positioned immediately above the electrolyte injection unit, then detection precision is improved, but manufacturing precision requirements increase
Solution Approach 1:
The gas sensor is positioned at a specific location (immediately above the electrolyte injection unit) where electrolyte leakage is most likely to occur first. This localized positioning maximizes detection precision for the critical leakage point while the cap assembly structure provides natural alignment that reduces manufacturing precision requirements.
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
The solution effectively and promptly detects electrolyte leakage, initiating protective measures to prevent accidents and ensure battery safety by stopping charge/discharge operations and discharging the battery, thus mitigating risks associated with leakage.
Implementation Method 1
the gas sensor may be a pressure sensor that detects a leakage of the electrolyte into the cap assembly by detecting an increase in vapor pressure in the cap assembly caused by the leakage of the electrolyte into the cap assembly
Implementation Method 2
the gas sensor detects a leakage of the electrolyte into the cap assembly by a change in resistance or electric capacity of the gas sensor caused by contact of the electrolyte with the gas sensor
Data Source
AI summary
A battery having a can containing an electrode assembly and an electrolyte and a cap assembly with a cap plate having an electrolyte injection unit, the cap plate is coupled to the can and an upper cover is coupled to the cap plate. The battery further includes a gas sensor located within the cap assembly to detect leakage of the electrolyte into the cap assembly and a protective circuit module mounted to the upper cover and electrically coupled to the gas sensor, the protective circuit module is adapted to stop a charge/discharge operation of the battery and discharge the battery upon receipt of a signal from the gas sensor indicating detection of leakage of the electrolyte into the cap assembly.