Traction Battery Sensor Placement for Leak Detection

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Solution Overview

Problem

Current traction batteries in motor vehicles lack a comprehensive functional check mechanism to detect gas leaks and contaminant ingress, limiting their reliability and maintenance capabilities.

Innovation Solution

Incorporating particle sensors and gas sensors within the battery housing or module housings of the traction battery to monitor for gas outgassing and contaminant ingress, with optional temperature and pressure sensors for evaluating leaktightness, enabling a more detailed functional assessment of individual battery modules and the overall battery system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If no sensors are arranged in the battery housing, then the device complexity is low, but the measurement precision and reliability of battery functional checks are insufficient

Engineering Contradiction:

Improvedetection capabilityVSAvoidsensor arrangement

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent divides the battery system into modular sections (battery housing and module housings) and places sensors at different hierarchical levels. Particle sensors are arranged in the battery housing to monitor overall contamination, while gas sensors are placed in individual module housings to detect localized outgassing. This segmented sensor distribution enables comprehensive monitoring without requiring a single complex sensor system throughout the entire battery.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces sensor systems as intermediary detection elements between the battery components and the external environment. These sensors act as mediators that translate physical phenomena (particle ingress, gas outgassing) into detectable signals, enabling indirect monitoring of battery health without direct intervention in the battery's operational components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If sensors are arranged in individual module housings, then the reliability of individual module monitoring is improved, but the device complexity increases

Engineering Contradiction:

Improvemodule-level detectionVSAvoidsensor distribution

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements segmentation by placing gas sensors in individual module housings rather than using a single centralized sensor system. This allows each battery module to be monitored independently for outgassing, enabling localized fault detection and isolation. The segmented approach improves reliability by allowing identification of specific problematic modules while keeping the overall system complexity manageable through modular sensor placement.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If comprehensive sensor systems are implemented, then the functional check capability is enhanced, but the manufacturing cost increases

Engineering Contradiction:

Improvefunctional check capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent employs segmentation to distribute sensor functions across multiple locations (battery housing and module housings) rather than implementing a single comprehensive sensor system. This modular sensor placement provides versatile functional check capability while managing manufacturing costs by using standardized sensor units at discrete locations, facilitating easier integration and potential cost optimization through volume procurement of identical sensor components.

Inventive Principle:

Principle #1Segmentation

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 setup allows for a more extensive and precise check of battery modules and the entire battery system, detecting outgassing and contaminant ingress, thereby enhancing the reliability and maintenance of traction batteries by identifying potential issues early.

Implementation Method 1

The respective particle sensor detects the ingress of contaminants from outside the battery housing into an interior of the battery housing

Methodology Applied

Scientific EffectParticle detection:

Implementation Method 2

The respective gas sensor detects outgassing of battery cells into an interior of the respective module housing

Methodology Applied

Scientific EffectGas detection:

Data Source

PatentUS11545701B2Traction battery of a motor vehicle

Publication Date: 2023.01.03 DR ING H C F PORSCHE AG

AI summary

A traction battery of a motor vehicle includes a battery housing, and a plurality of battery modules which are arranged in the battery housing. Each battery module has a module housing and battery cells which are accommodated in the respective module housing. At least one particle sensor and/or at least one gas sensor are/is arranged in the battery housing.