Battery Leak Test Device Using Conductive Electrolyte
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Solution Overview
Problem
Conductive outer layers on portable electronics batteries pose challenges for leak detection, as traditional methods fail to differentiate between defective and non-defective batteries due to the conductive nature of the anti-static film, and the batteries' sealed design prevents pressure changes or gas absorption, making it difficult to detect leaks.
Innovation Solution
A leak test device and method using a chamber with a conductive element, high voltage portions, and a microprocessor to ionize ambient air and measure current, allowing for effective detection of leaks without allowing significant electricity to leak through the conductive film, and using a vacuum or UV light to aid in ionization and detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional high voltage leak test methods are used on batteries with conductive outer layers, then electricity can be applied to detect leaks, but the conductive anti-static film causes excessive current leakage that makes it impossible to differentiate defective from non-defective batteries
Solution Approach 1:
The patent introduces a liquid electrolyte as an intermediary medium between the high voltage electrode and the battery's conductive outer layer. The electrolyte allows controlled ion conduction while the conductive film blocks direct electron conduction, creating a measurable resistance difference between leaking and non-leaking batteries without excessive current
Solution Approach 2:
The patent changes the conduction mechanism from electron conduction (through the conductive film) to ion conduction (through the electrolyte). This parameter change allows the high voltage test to work effectively because ions can be controlled to flow through leaks in the battery seal but not through the conductive film, enabling accurate leak detection
2Volume of moving object
If the battery is completely sealed with no empty space inside, then the battery design is compact and efficient, but pressure changes cannot occur to enable traditional leak detection methods
Solution Approach 1:
The patent uses liquid electrolyte that can move and respond to pressure changes within the sealed battery. When a leak occurs, the electrolyte flows out through the defect, and this fluid movement creates a measurable change in electrical resistance and conductivity, enabling leak detection without requiring internal air pressure changes
3Measurement precision
If tracer gas charging or volatile organic compound detection is used for leak testing, then these methods can detect leaks in some applications, but the sealed battery design prevents gas absorption and the leaked fluids dry up and seal the hole
Solution Approach 1:
The patent replaces mechanical/chemical leak detection methods (tracer gas, VOC detection, pressure changes) with an electrical measurement system. The system uses high voltage to create ion conduction through the electrolyte, measuring electrical resistance changes to detect leaks, which is more suitable for completely sealed batteries than traditional mechanical methods
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
Enables accurate detection of leaks in batteries with conductive outer layers by preventing current leakage during testing and using ionization and vacuum to enhance detection sensitivity, overcoming the limitations of traditional methods.
Implementation Method 1
A leak test device and method using a chamber with a conductive element, high voltage portions, and a microprocessor to ionize ambient air and measure current
Implementation Method 2
using a vacuum or UV light to aid in ionization and detection
Data Source
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AI summary
A testing device and method may be implemented for improved detection of leaks in batteries used in portable electronic devices. The leak testing device may include a chamber configured to hold a device under test. The chamber may include a conductive foam, a conductive liquid, or any suitable conductive material. The chamber may be configured to hold the device under test in a substantially airtight environment and prevent or reduce air ionization under high voltage. The device under test may be a battery that has a conductive outer layer.