This document pertains generally, but not by way of limitation, to monitoring gas concentration in an environment, such as in an electric vehicle or other battery environment.
A battery can include a battery cell or a battery module, either of which can be included in a battery pack or a battery compartment. It is desirable to monitor battery health such as to anticipate or detect thermal runaway accompanying battery failure. Early detection is helpful because a thermal runaway event can lead to a battery fire or explosion. In automotive applications, early detection and alerting of signs of battery failure or thermal runaway can help allow a passenger to timely exit a vehicle to reach safety.
Battery health can be monitored at the battery cell level, at a battery module level, or at a battery pack level, such as by using a temperature sensor in a battery compartment to detect a thermal runaway event. While one approach to monitoring battery health can include using a pressure sensor to measure pressure within a battery compartment, a battery pack will generally include a pressure equalization vent, which can make slow pressure changes hard to detect, such that pressure-based battery failure detection can be limited to being later than desirable in the failure progression when stronger pressure changes occur. Such a pressure sensor can also be affected by unrelated events as well as being difficult to use for detecting battery failure before the start of a thermal runaway event.
Battery health can also be monitored using one or more gas sensors to monitor gas composition in the battery environment, such as within a battery compartment headspace. An optical non-dispersive infrared (NDIR) sensor can be used for gas detection, such as to detect CO2 or CO. However, CO2 and CO may only appear at that late stage of battery failure at which thermal runaway is fairly immediately imminent. Battery health monitoring via volatile gas sensing can use one or more Metal oxide sensors to detect battery failure at an earlier stage of the failure progression. However, metal oxide sensors have limited longevity. In operation, the heated metal oxide layer of a metal oxide sensor can become contaminated. Such contamination can significantly change the sensor response, rendering the sensor unusable, particularly in demanding applications. For example, automotive and industrial batteries may require a usable lifetime of more than 10 years.
The present inventors have recognized, among other things, the need for a robust approach to monitoring battery health that is not susceptible to external influence, and the need for an approach to monitoring battery health that can detect battery failure early in the battery failure progression, such as before the onset of thermal runaway event. The present techniques can help provide a solution to this problem. The present techniques can include monitoring a thermal property of a gas in an environment for one or more changes potentially indicative of battery health. When a primary change indicator is met by monitoring the thermal property, then a secondary change indicator can be measured and compared to at least one criterion. For example, a secondary gas sensor can be switched on or into an operating mode and used to further determine, based on a measured concentration of a gas composition component, whether the primary change indicator does indeed rise to being a sign of battery failure. Similar gas monitor techniques can also be useful in applications other than automotive battery health monitoring.
This overview is intended to provide an overview of subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the invention. The detailed description is included to provide further information about the present patent application.
In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.
This document describes, among other things, techniques that can include a gas monitoring system for monitoring gas in a battery compartment, such as can be associated with a battery pack, battery module, battery cell, or other environment of interest. The system can include a thermal property primary gas sensor, such as to detect a thermal property of an environment, such as thermal conductivity of the environment, a heat capacity of the environment, or a thermal diffusivity of the environment. The primary gas sensor can be configured to provide a triggering output in response to a determined change in a thermal property of the environment, from which a change in a gas composition of the environment can be inferred. Then, in response to the triggering output from the thermal property primary gas sensor, a chemical concentration secondary gas sensor (such as a metal oxide (“MOx”) chemical concentration sensor) can be enabled, such as for being placed into an operating mode for detecting an amount of a specified first gas component in the environment.
Examples of one or more thermal properties detectable by the primary gas sensor can include, among other things, a thermal conductivity of the environment, a heat capacity of the environment, or a thermal diffusivity of the environment—one or more of which may vary with the gas composition of the environment. In a particular example, an electrical resistance or conductivity of a heater element associated with the secondary gas sensor can be used as the thermal property of the primary gas sensor. The primary sensor can trigger enabling of the second sensor, such as by elevating the temperature of a heater element of the secondary sensor from a standby temperature to an operating temperature at which the secondary sensor can detect a concentration of a first gas component in the environment.
For battery monitoring, a nearby gas composition, such as in the headspace of a battery compartment, can be monitored to help with early detection of battery failure. This can help to make a battery safer by allowing early detection of a potential catastrophic failure. Earlier detection of a potential catastrophic failure may help a battery management or other system to react to the detected event, such as to start responding with a corrective action or to notify the user of the potential failure. Corrective action can include disconnecting or discharging an affected battery compartment, increasing cooling to counteract heating that may be leading to a thermal runaway event, or limiting demand on the battery, one or more of which may help to halt or reverse the battery failure or thermal runaway. For example, the gas monitoring system can be used to detect one or more volatile gases that may indicate imminent failure of a battery in the headspace of a battery compartment.
A battery at an early stage of failure, may primarily produce, in the case of electrolyte leakage, gases such as Ethylene Carbonate (“EC”), Dimethyl Carbonate (“DMC”), Diethyl Carbonate (“DEC”), and Ethyl Methyl Carbonate (“EMC”). In the case of electrolysis of water, a battery may primarily produce gases such as H2 and O2. A battery at a later stage of battery failure, the so called “first venting”, may primarily produce gases such as DEC, DMC, EMC, and H2O, as well as producing lesser amounts of gases such as CO, CO2, EC, and C4H10. A battery at a stage of battery failure where combustion is fairly immediately imminent, the so called “thermal runaway”, may primarily produce gases such as CO2, CO, C2H4, and H2 as well as lesser portions of gases such as C2H2, C2H6, CH4, DEC, DMC, EMC, H2O, C4H10, and O2. A battery that has combusted may primarily produce gases such as CO, CO2, and HF. [see, Essl, Christiane, Lauritz Seifert, Michael Rabe, and Anton Fuchs. “Early Detection of Failing Automotive Batteries Using Gas Sensors”. Batteries 7, no. 2 (June 2021): 25. https://doi.org/10.3390/batteries7020025.]
These volatile gases may be detectable in an ambient gas environment 204, such as in the headspace 103 of the battery compartment 101. Gases, such as those generated by electrolytes such as Ethylene Carbonate, Dimethyl Carbonate, Diethyl Carbonate, or Ethyl Methyl Carbonate may be produced at an early stage of battery failure. A change in gas composition of the ambient gas environment 204 due to the addition of a volatile gas can cause a change in a thermal property of the ambient gas environment 204, such as if a thermal property of the volatile gas is significantly different from the ambient gas environment 204, before adding the volatile gas. Quite a number of volatile gases may have a thermal property that is significantly different from that same thermal property of air.
Table 1 below lists thermal conductivity, specific heat capacity, thermal diffusivity, and density of Air, N2, CO2, O2, H2, He, and CH4. (see, Kliche, Kurt, et al. “Sensor for thermal gas analysis based on micromachined silicon-microwires.” IEEE Sensors Journal 13.7 (2013): 2626-2635.) Table 1 shows that thermal conductivity, thermal diffusivity, or heat capacity may be used for selective sensing of a particular gas in a mixture. In addition, the inventors have observed experimentally that the thermal properties of a target volatile battery gas to be detected, e.g., DMC electrolyte volatiles may have thermal properties that can be different enough from the thermal properties of ambient air such that, at the detection concentrations of interest, changes in such thermal properties can be used to infer changes in concentration of various gas components in the ambient air in the environment of the battery space. Thus, one or more thermal properties can be used to detect the presence of DMC electrolyte volatiles and other volatile battery gas components of interest—at least to a degree helpful to trigger a more accurate secondary gas concentration sensor that need not rely on inferred gas concentration from thermal properties in the environment. For example, such a secondary gas concentration sensor can directly identify concentration of a target gas component in the ambient air of the environment near the battery. As an illustrative example, a gas component (e.g., CO2) having at least about a 30% difference from air in a specified thermal property can be detected at concentrations of interest using a primary thermal property gas concentration sensor, and then more accurately determined using a more accurate secondary gas concentration sensor than the primary thermal property gas concentration sensor.
Therefore, the ambient gas environment 204 in the headspace 103 of the battery compartment 101 may be monitored for a change in one or more thermal properties indicating battery failure or thermal runaway.
However, the MOx layer of a MOx gas concentration sensor can become contaminated while it is heated to its operating temperature. Therefore, in prolonged operation, the response of the MOx gas concentration sensor can change significantly over time, reducing its reliability. At temperatures below 100° C., contamination of the MOx layer can be reduced significantly, and the power consumption of the MOx gas concentration sensor can also be reduced when only heating the MOx sensor to such lower temperature. However, the sensitivity of a MOx gas concentration sensor drops significantly at lower temperatures and can be unusable at temperatures below 100° C. A MOx gas concentration sensor 300 may include a substrate 301. The substrate 301 may be connected by a hotplate member 302 to support a hotplate 400, including a heater element 203. The hotplate member 302 can also support a metal oxide layer 303, and a metal oxide sensing electrode 304. The hotplate member 302 can help to thermally isolate the metal oxide layer 303, the metal oxide sensing electrode 304, and the heater 203 from the substrate 301. Such thermal isolation can include creating a thermal isolation cavity 305, which can be capable of receiving ambient or other gas from an ambient gas environment 204, for example, such as a headspace 103 of a battery compartment 101 or other environment. The hotplate 400 and the heater element 203 may be arranged to heat the metal oxide sensing electrode 304 and the metal oxide layer 303. Once heated, the metal oxide sensing electrode 304 can be used to measure an electrical resistance or conductivity of the metal oxide layer 303, which will change as a function of the extent to which the metal oxide layer 303 has been oxidized. This is because the oxidation of the metal oxide layer 303 is dependent on the concentration of a specified gas component in an ambient gas environment 204 surrounding the metal oxide layer 303.
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Such techniques can offer several benefits. Using multiple measurement principles provides built-in redundance. This can help inhibit or prevent potential false readings. By monitoring the heater element 203 at a temperature below 100° C., the gas monitoring system 100 can help increase the lifespan of the system significantly over that of a MOx gas concentration sensor 300 alone. This is because the MOx gas concentration sensor 300 can generally be kept below the operating or other temperature at which the MOx layer is significantly contaminated until the thermal property primary sensor 200 provides an initial indication of a potential concern for battery failure, at which time the secondary sensor can be engaged, but not otherwise. The gas monitoring system 100 may also help reduce overall power consumption significantly compared to a MOx gas concentration sensor 300 alone, as the power consumption of a MOx gas concentration sensor 300 depends on the amount of heating used to provide the (standby or operating) temperature of the MOx gas concentration sensor 300.
Other examples of the gas monitoring system 100 can be configured to use a different type of primary sensor 200 than a “hot-wire” thermal property sensor 200, such as a sensor using the “three-omega” method, or a different type of gas concentration secondary sensor 201 than a MOx gas concentration sensor 300. Other examples of the gas monitoring system 100 can include a thermal property primary sensor 200 and a gas concentration secondary sensor 201 that do not share a heater element 203, or are not incorporated into a single device. The gas monitoring system 100 may be configured as a system in package or fully monolithically integrated. The gas monitoring system 100 may also be implemented using separate, discrete sensors and other electronic components.
The gas monitoring system 100 may include one or more additional or alternative primary or secondary sensors. For example, an additional gas concentration secondary sensor may be configured to detect the same or different gas species or concentrations as the gas concentration secondary sensor 201. The additional secondary sensor may include a MOx layer 303 configured with a different composition than the first MOx gas concentration sensor 300. This can help provide additional functionality or flexibility in selecting a specified gas component to monitor, which may help provide improved selectivity. The gas monitoring system 100 may include one or more additional auxiliary thermal property or other primary sensors. The one or more additional thermal property sensor may be configured to monitor the same or different thermal property as the thermal property primary sensor 200. The gas monitoring system 100 may include an NDIR sensor configured as a primary or secondary sensor.
Enabling a gas concentration secondary sensor 201 may include increasing the temperature of the gas concentration secondary sensor 201 to an operating temperature at which gas concentration detection operation is possible, or the powering on of the gas concentration secondary sensor 201.
The gas monitoring system 100 may include one or more ambient environmental condition sensors such as can be configured to monitor an ambient environmental condition (other than gas composition concentration), such as ambient temperature, humidity, flow, or barometric pressure, such as for use in combination with the thermal property primary sensor 200 and gas concentration secondary sensor 201 to help improve the accuracy of the gas monitoring system 100.
The gas monitoring system 100 may include one or more pairs of thermal property primary sensor 200, which may include at least a first thermal property primary sensor 200 and a second thermal property primary sensor 200 that have been paired together, and one or more pairs of gas concentration secondary sensors 201, which may include at least a first gas concentration secondary sensor 201 and a second gas concentration secondary sensor 201 that have been paired together. The first thermal property primary sensor 200 and first gas concentration secondary sensor 201 can be configured to monitor the environment of interest, such as the headspace 103 of a battery compartment 101. The second thermal property primary sensor 200 and the second gas concentration secondary sensor 201 can be placed in a environment with a known and unchanging gas composition, such as an enclosure filled with a known gas. The gas monitoring system 100 can compare the measurement, such as by performing a differential measurement, of the first thermal property primary sensor 200 and the first gas concentration secondary sensor 201 to the measurements of the second thermal property primary sensor 200 and the second gas concentration secondary sensor 201. The gas monitoring system 100 can also use the first thermal property primary sensor 200 and second thermal property primary sensor 200 for Differential Scanning calorimetry, which can help accurately determine the specific heat capacity of an ambient gas environment 204.
The gas monitoring system 100 may be used for other volatile gas monitoring applications such as hydrogen, methane, or difluoromethane leak detectors. The gas monitoring system 100 may also be used for applications such as creating an accurate air quality sensor, such as for populated environments.
Using primary sensor heater resistance measurements with a resolution of 22 bits or better can help ensure that measurements are sufficiently sensitive. Total analog-to-digital converter resolution requirements can be reduced by using one or more offset compensation techniques in the overall signal chain.
A thermal resistance of the heater element being above 10,000 K/W can help ensure reliable function of a “hot-wire” thermal conductivity sensor.
Configuring the system in the smallest reasonable form factor may help reduce the cost of the system. For example,