Battery Module Impedance Sensing for Electrolyte Leak Detection
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Solution Overview
Problem
Existing energy storage modules, such as lithium ion batteries and ultracapacitors, face challenges in efficiently detecting and locating electrolyte leakage, which can indicate imminent or catastrophic failure, and existing systems are complex and not easily integrated into manufacturing processes.
Innovation Solution
A leakage sensor arrangement using a coil-like sensor member on a substrate to measure impedance changes caused by electrolyte leakage, employing an evaluation unit to determine the presence and location of electrolyte based on magnetic field interactions, allowing for simpler integration and effective prevention of catastrophic failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex monitoring systems with multiple sensors are used to detect electrolyte leakage, then detection reliability is improved, but device complexity increases
Solution Approach 1:
The invention extracts the essential detection function from complex multi-sensor systems and implements it through a single coil-like sensor member that generates a magnetic field. This magnetic field interacts with electrolyte leakage to produce detectable impedance changes, eliminating the need for multiple sensors while maintaining detection reliability
Solution Approach 2:
The invention replaces complex mechanical or electronic sensor systems with a magnetic field-based detection mechanism. The coil-like sensor member generates a magnetic field that interacts with the electrolyte, and impedance changes are measured electrically rather than through mechanical means, simplifying the overall system
2Reliability
If advanced leakage detection systems are integrated into energy storage modules, then operational safety is improved, but manufacturing complexity increases
Solution Approach 1:
The coil-like sensor member serves multiple functions: it generates the magnetic field for detection, acts as the sensing element through impedance measurement, and can be integrated into existing circuit boards. This multi-functionality reduces the number of additional components needed during manufacturing
Solution Approach 2:
The magnetic field acts as an intermediary between the electrolyte leakage and the detection system. Instead of requiring direct contact or complex sensor integration, the magnetic field mediates the interaction, allowing simple coil placement on circuit boards without complex assembly procedures
3Measurement precision
If fluorescent material and ultraviolet radiation systems are used for leakage detection, then leakage visibility is improved, but device complexity and production integration difficulty increase
Solution Approach 1:
The invention replaces optical detection methods (fluorescent material and ultraviolet radiation) with electromagnetic induction-based impedance measurement. The coil-like sensor detects electrolyte leakage through changes in electrical impedance caused by magnetic field interaction, eliminating the need for fluorescent materials and UV light sources
Solution Approach 2:
The invention extracts the detection capability from complex optical systems and implements it through a simple electrical impedance measurement circuit. The essential function of detecting electrolyte presence is achieved through magnetic field interaction and impedance change measurement, removing unnecessary optical components
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 system provides sensitive and reliable detection of electrolyte leakage, enabling proactive counter-measures like shutdown or isolation, and avoids complex re-designs, effectively preventing catastrophic events by detecting leaks before decomposition occurs.
Implementation Method 1
at least one coil-like sensor member that is operatively coupled to the evaluation unit
Implementation Method 2
measuring an impedance value of the monitoring portion and for determining the presence of emanating electrolyte from the energy storage cell due to an impedance change
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A leakage sensor arrangement (30) configured for detecting leaking of an electrolyte (32) out of an energy storage cell (16) comprises an energy storage cell (16) including an electrolyte (32); a substrate (20); at least one monitoring portion (22) that is arranged on the substrate (20) so as to be capable to interact with emanating electrolyte (32) from the energy storage cell (16) by means of impedance; and an evaluation unit (26) that is operatively coupled to the monitoring portion (22) and configured for measuring an impedance value of the monitoring portion (22) and for determining the presence of emanating electrolyte (32) from the energy storage cell (16) due to an impedance change between a predetermined impedance value (Zbase) and a measured impedance value (Z) or between at least two measured impedance values (Z).