Stacked Electrode Sensor Arrays for Fast-Charging Battery Monitoring
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Solution Overview
Problem
Current electrochemical devices in electric-drive vehicles lack efficient methods for in situ monitoring of electrode operating characteristics, leading to suboptimal charging capabilities and potential issues like micro short circuits and non-uniform electrode aging.
Innovation Solution
Incorporation of in-stack sensor arrays within the electrode stack of lithium-class battery cells, comprising voltage sensing leads and a reference electrode, to monitor electrode voltages and temperatures in real-time, enabling accurate fast charging and detection of micro short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional electrochemical devices are used without in-stack sensors, then the device structure remains simple and manufacturing cost is lower, but the capability to monitor electrode operating characteristics in situ is insufficient
Solution Approach 1:
The sensor assembly is nested within the electrode stack structure, with sensing leads positioned between electrode layers and a reference electrode embedded in the separator. This nested configuration allows comprehensive in-stack monitoring while maintaining a compact form factor that integrates seamlessly with the existing battery architecture.
Solution Approach 2:
The in-stack sensor system serves multiple functions simultaneously: it monitors voltage distribution across electrodes, detects temperature gradients, identifies micro short circuits, and provides data for both fast charging control and regenerative calibration. This multi-functionality resolves the contradiction by delivering comprehensive monitoring capabilities through a unified sensor infrastructure.
2Speed
If fast charging is implemented without in-stack voltage monitoring, then charging speed increases, but the risk of micro short circuits and non-uniform electrode aging increases
Solution Approach 1:
The sensor assembly provides real-time feedback on electrode voltage distribution and operational characteristics during fast charging. This feedback enables the battery management system to dynamically adjust charging parameters, ensuring uniform electrode aging and immediate detection of micro short circuits while maintaining high charging speeds.
Solution Approach 2:
The in-stack sensors are installed beforehand within the electrode stack to establish baseline voltage distributions and monitoring capabilities before fast charging begins. This preliminary configuration enables immediate detection of anomalies and proactive adjustment of charging parameters to prevent micro short circuits and non-uniform aging.
3Measurement precision
If multiple voltage sensing leads are attached to monitor discrete regions, then voltage mapping precision improves, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The voltage sensing function is segmented into multiple discrete sensing leads, each attached to specific regions of the electrode stack. This segmentation enables precise localized voltage measurement while allowing modular assembly, where individual sensing leads can be positioned and connected independently, reducing overall assembly complexity.
Solution Approach 2:
The separator serves as an intermediary substrate that facilitates the attachment of multiple voltage sensing leads to discrete electrode regions. By providing a common mounting surface and electrical isolation, the separator simplifies the manufacturing process while enabling comprehensive voltage mapping across the electrode stack.
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
Enhances fast charging capabilities, improves regenerative calibration, and increases driving range and pack performance by providing comprehensive mapping of electrode voltages and detecting micro short circuits.
Implementation Method 1
An electrically insulating separator is interposed between each neighboring pair of working electrodes, the separator configured to transmit therebetween ions of the electrolyte
Implementation Method 2
Each sensing lead abuts a discrete region of a working electrode and connects to a respective sensing device to transmit thereto one or more electrical signals indicative of an electrical characteristic
Implementation Method 3
an electrolyte composition that is chemically configured to conduct ions
Data Source
AI summary
Presented are electrochemical devices with in-stack sensor arrays, methods for making/using such electrochemical devices, and lithium-class battery cells with stacked electrode assemblies having in-stack sensor arrays. An electrochemical device includes a device housing that stores an electrolyte composition for conducting ions. An electrode stack, which is located inside the device housing in electrochemical contact with the electrolyte, includes at least two working electrodes. An electrically insulating and ionically transmissive separator is interposed between each neighboring pair of working electrodes. A reference electrode is attached to one side of the separator and connected to multiple electrical sensing devices. Multiple electrical sensing leads are attached to another side of the separator, opposite the reference electrode, with each abutting a discrete region of a working electrode and each connecting to one of the sensing devices to transmit thereto electrical signals indicative of an electrical characteristic (e.g., voltage) of the discrete region it contacts.