Battery Sensor Cathodic Protection Without Cladding
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Solution Overview
Problem
Accumulator cell sensors are prone to corrosion when exposed to the electrolyte atmosphere, leading to premature failure and increased manufacturing costs due to the need for protective cladding, which also impairs their response behavior.
Innovation Solution
The use of sensor electrodes operated in an electrical potential range that opposes corrosion, eliminating the need for protective cladding by applying a voltage to prevent corrosion, thus employing cathodic corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are protected by a cladding to prevent corrosion from electrolyte exposure, then the service life of sensors is extended, but the response behavior of sensors deteriorates and manufacturing costs increase
Solution Approach 1:
The patent changes the electrical potential parameter of the sensor electrodes to operate within a specific range (greater than 0 V to 3 V, preferably 0.1 V to 2 V) relative to the electrolyte. This parameter change creates cathodic protection that prevents corrosion without requiring physical cladding, thus maintaining sensor response behavior while extending service life.
2Reliability
If sensors are protected by a cladding to prevent corrosion, then corrosion damage is reduced, but manufacturing costs increase
Solution Approach 1:
The patent extracts and eliminates the cladding component from the sensor assembly by replacing it with an electrical cathodic protection system. The sensor electrodes are directly exposed to the electrolyte but protected through controlled electrical potential, simplifying manufacturing and reducing costs while maintaining corrosion protection.
3Device complexity
If sensors are operated without cladding to improve response behavior and reduce costs, then manufacturing costs decrease and response behavior improves, but corrosion damage occurs
Solution Approach 1:
The sensor system provides its own corrosion protection through the cathodic protection mechanism. By operating the sensor electrodes within a specific electrical potential range, the sensors protect themselves from corrosion without requiring external protective structures, thereby maintaining both response behavior and reliability.
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
This approach provides lasting corrosion protection, improves sensor response behavior, and reduces manufacturing costs by allowing direct exposure to the electrolyte without special precautions, enabling flexible application and simpler circuitry.
Implementation Method 1
The at least two sensor electrodes are operated in an electrical potential range with respect to the electrolyte that protects the sensor and/or the sensor electrodes from corrosion by the electrolyte. Due to a voltage opposing the corrosion potential being applied to the sensor electrodes, a corrosion of the sensor is prevented and it is possible to completely omit a protective cladding. This type of active corrosion protection constitutes a cathodic corrosion protection.
Data Source
AI summary
A rechargeable battery cell includes a cathode, an anode, an electrolyte, and a sensor that is arranged in the rechargeable battery cell. The sensor has at least two sensor electrodes and is accommodated in the rechargeable battery cell without a sheathing at least in sections. Moreover, the at least two sensor electrodes are operated in an electrical potential range that protects the sensor and/or the sensor electrodes against corrosion by the electrolyte. A method for producing and operating a rechargeable battery cell of this kind is also provided.