Wireless Battery Leak Detection via Capacitive Sensing
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Solution Overview
Problem
Current battery leak detection systems are unable to accurately pinpoint leak locations in batteries, relying on cumbersome and unreliable chemical vapor detection or optical changes, which can lead to catastrophic fires and safety hazards in applications like electric vehicles and medical devices, due to their poor sensitivity and inability to localize leaks.
Innovation Solution
A wireless battery leak detection system using localized capacitive measurements with conductive leads and a small measurement and control chip that can detect changes in capacitance when bridged by ionically conductive species, allowing for precise leak identification and wireless communication to the battery management unit for remediation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chemical vapor detection systems are used to detect battery leaks, then leak detection capability is provided, but the system becomes cumbersome and unreliable with poor sensitivity and inability to pinpoint leak locations
Solution Approach 1:
The battery pack is divided into multiple individual cell monitoring units, each with its own sensor and processing capability. Each cell has dedicated conductive leads and measurement circuits that independently monitor for leaks, allowing localized detection without requiring a centralized complex vapor detection system for the entire battery pack.
Solution Approach 2:
The patent replaces chemical vapor detection systems with an electrical measurement system using conductive leads and capacitance measurement circuits. Instead of using chemical sensors to detect vapor, the system uses electrical properties (capacitance changes) to detect the presence of electrolyte leaks, eliminating the need for bulky chemical detection equipment.
2Measurement precision
If optical or electrical measurements are used for leak detection, then large leaks can be detected, but the sensitivity is poor and leak locations cannot be localized
Solution Approach 1:
Each battery cell is equipped with localized measurement circuits and conductive leads positioned at specific locations on the cell. The capacitance measurement is performed locally at each cell rather than using a centralized sensor, enabling both sensitive detection and precise localization of leaks to specific cells or regions.
Solution Approach 2:
The patent introduces conductive leads as intermediary elements that extend from the measurement circuit to the cell surface. These leads act as sensors that detect capacitance changes caused by electrolyte leakage, providing both sensitive measurement capability and spatial information about where the leak occurs based on which lead detects the change.
3Measurement precision
If wireless measurement and communication chips are implemented in each cell, then localized leak detection is achieved, but device complexity increases
Solution Approach 1:
The measurement circuit and communication functionality are merged into a single integrated chip that is placed on or near each battery cell. This combination eliminates the need for separate wired connections for both measurement and communication, reducing overall system complexity while maintaining localized detection capability. The wireless communication feature allows data transmission without additional harness wires.
Solution Approach 2:
Each cell's measurement circuit operates autonomously, performing self-diagnosis and wireless communication of its status. The circuit continuously monitors its own cell for leaks and automatically transmits alerts when anomalies are detected, without requiring manual intervention or complex centralized control systems to manage each cell individually.
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 sensitive detection of small electrolyte leaks, preventing fires and ensuring personnel safety by accurately localizing leaks and facilitating timely remediation, such as isolating the affected battery module or alerting users to replace the cell.
Implementation Method 1
a wireless measurement and communication chip ('chip') configured to perform capacitive measurement, showing a change in capacitance when bridged by ionically conductive species
Implementation Method 2
showing a change in capacitance when bridged by ionically conductive species or when a wick is suffused with an electrolyte
Data Source
AI summary
An apparatus for detecting leaks in a battery includes a plurality of cells, each which include a pair of conductive leads bracketing a polymer seal, and a wireless measurement and communication chip (“chip”) configured to perform capacitive measurement, showing a change in capacitance when bridged by ionically conductive species or when a wick is suffused with an electrolyte.