Battery Pack Electrolysis Detection and Remediation
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Solution Overview
Problem
Electric vehicle battery packs face the risk of runaway thermal conditions due to high voltage electrolysis, which can lead to overheating and hydrogen gas buildup, posing safety hazards, and existing solutions struggle to safely stop these reactions.
Innovation Solution
A detection and remediation system using sensors to monitor parameters like humidity, hydrogen gas, temperature, pressure, voltage, current, coolant flow rate, and immersion to identify high voltage electrolysis, followed by remediation actions such as opening a short circuit, adding coolant, or flooding with water to prevent thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant is used to cool battery packs, then thermal management is improved, but the risk of electrolysis and hydrogen gas buildup increases
Solution Approach 1:
The patent introduces an inert gas atmosphere (nitrogen or carbon dioxide) as an intermediary between the coolant and the battery terminals. This mediator prevents the coolant from coming into contact with electrical components, eliminating the electrolysis reaction while maintaining the cooling function. The inert gas acts as a physical barrier that allows thermal management without the harmful side effects of direct coolant-contact cooling.
Solution Approach 2:
The patent creates an inert atmosphere within the battery enclosure by filling it with nitrogen or carbon dioxide gas. This inert environment prevents the conductive coolant from causing electrolysis reactions when it contacts electrical components. The inert atmosphere suppresses the harmful chemical reactions while allowing the cooling system to function, directly resolving the contradiction between effective cooling and electrolysis prevention.
2Temperature
If high voltage electrolysis occurs, then cooling effect is enhanced, but thermal runaway risk increases
Solution Approach 1:
The patent applies preliminary anti-action by pre-filling the battery enclosure with inert gas before any electrolysis can occur. This preventive measure stops the electrolysis reaction before it can generate excessive heat and lead to thermal runaway. The inert atmosphere is established in advance to counteract the potential harmful effects of coolant-contact electrolysis, allowing safe operation of the cooling system.
Solution Approach 2:
The inert gas serves as an intermediary that allows the cooling system to function effectively while preventing the electrolysis reaction that would otherwise occur. By placing this mediator between the coolant and electrical components, the system achieves the desired cooling effect without the dangerous side effect of thermal runaway, resolving the contradiction between cooling performance and safety.
3Measurement precision
If multiple sensors are deployed to detect electrolysis, then detection accuracy is improved, but system complexity increases
Solution Approach 1:
The patent employs sensors that serve multiple functions: temperature sensors detect both thermal conditions and electrolysis-induced heating, humidity sensors detect both moisture and electrolysis products, and pressure sensors monitor both system pressure and gas buildup from electrolysis. This multi-functionality allows accurate electrolysis detection without requiring a separate dedicated sensor for each parameter, thereby maintaining detection accuracy while limiting system complexity.
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
Effectively detects and responds to high voltage electrolysis, preventing thermal runaway and reducing the risk of hydrogen gas buildup, thereby ensuring the safety and stability of electric vehicle battery packs.
Implementation Method 1
an integrated and isolated cooling system that routes coolant throughout the enclosure
Implementation Method 2
coolant from the cooling system that routes coolant throughout the enclosure
Implementation Method 3
the coolant may be electrically conductive and can bridge terminals having relatively large potential differences. That bridging may start an electrolysis process in which the coolant is electrolyzed
Implementation Method 4
the coolant will begin to boil when enough energy is conducted into the electrolysis
Data Source
AI summary
A battery pack includes an enclosure containing a plurality of battery modules. A cooling system disposed among and electrically isolated from the plurality of battery modules uses a coolant solution that is a first mixture of a first liquid and a second liquid in a predetermined ratio to produce a first boiling point. Boiling of the coolant solution changes the predetermined ratio to produce a second boiling point that is higher than the first boiling point and that is sufficient to induce a thermal runaway condition for the plurality of battery module. A sensor monitors at least one operational characteristic of the plurality of battery modules and a controller determines a possible high voltage electrolysis within the enclosure based upon the at least one operational characteristic. A remediation system is responsive to the possible high voltage electrolysis to decrease risks associated with the possible high voltage electrolysis when operated.