Optical waveguide methods for detecting internal faults in operating batteries

• US 9,570,781 B2
• Filed: 02/12/2015
• Issued: 02/14/2017
• Est. Priority Date: 08/10/2012
• Status: Active Grant

• Current Assignee: Battelle Memorial Institute
• Original Assignee: Battelle Memorial Institute
• Inventors: Saunders, James H., Morrow, C. Alexander, Risser, Steven M., Spahr, Kevin B.
• Primary Examiner(s): Williams, Arun
• Application Number:
  US14/620,568
• Publication Number:
  US 20150270584A1
• Time in Patent Office: 733 Days
• Field of Search: 324/426
• US Class Current: 1/1
• CPC Class Codes: H01M 10/4285 Testing apparatus
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 50/457 comprising three or more layers
• CPC Class Codes: H01M 50/491 Porosity
• CPC Class Codes: H01M 50/569 Constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals battery terminal connectors with integrated measuring arrangements G01R31/364
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

Light is transmitted from a light source through or from a separator of a battery cell and received by one or more light detectors. The light that is normally transmitted through the separator is scattered, absorbed, wavelength-shifted or otherwise distorted by an impending fault in the vicinity of or within the separator. The change in light due to the impending fault is measured by a detector and a signal from the detector is processed to identify the impending fault so that a warning can be generated indicative of the impending fault. In particular, the separator and a battery cell electrolyte can be selected to provide waveguide properties.

Claims

1. A battery structure for monitoring development of impending faults of a battery cell, the battery structure comprising:

a first electrode and a second electrode;

a battery cell separator formed of a light transmitting material that has light transmission characteristics that are a function of a state of impending faults of the battery cell;

wherein the battery cell separator comprises;

a core section,

a first cladding section between the core section and the first electrode, and

a second cladding section between the core section and the second electrode;

an electrolyte capable of passing through portions of the battery cell separator;

a light source, in optical communication with a first edge of the battery cell separator, for transmitting light, having a predetermined wavelength, into the battery cell separator; and

a light detector, in optical communication with a second edge of the battery cell separator, for receiving light transmitted through the battery cell separator,

wherein a fault state of a portion of the battery cell associated with the light detector can be determined based on the received light.

2. The battery structure of claim 1, wherein a first index of refraction of the electrolyte is substantially equal to a second index of refraction of the core section and the first and second indices of refraction are not substantially equal to a third index of refraction of the first and second cladding sections.

3. The battery structure of claim 2, wherein each of the first and second cladding sections comprises a plurality of pores which:

a) have a pore size less than or equal to half the predetermined wavelength; and

b) have pore spacing less than or equal to half the predetermined wavelength.

4. The battery structure of claim 2, wherein the first index of refraction and the second index of refraction are between about 1.49 and 1.51, and the third index of refraction is about 1.46.

5. The battery structure of claim 4, wherein the core section comprises polypropylene and each of the first and second cladding sections comprises porous glass.

6. The battery structure of claim 1, wherein a first index of refraction of the electrolyte is substantially equal to a second index of refraction of the first and second cladding sections and the first and second indices of refraction are not substantially equal to a third index of refraction of the core section.

7. The battery structure of claim 6, wherein the core section comprises a plurality of pores which:

a) have a pore size less than or equal to half the predetermined wavelength; and

b) have pore spacing less than or equal to half the predetermined wavelength.

8. The battery structure of claim 6, wherein the first index of refraction and the second index of refraction are about 1.42, and the third index of refraction is about 1.46.

9. The battery structure of claim 7, wherein:

a) the core section comprises porous glass;

b) the first cladding section comprises a first region between the core section and the first electrode containing a first portion of the electrolyte; and

c) the second cladding section comprises a second region between the core section and the second electrode containing a second portion of the electrolyte.

10. The battery structure of claim 1, wherein a first index of refraction of the electrolyte is:

a) different than a second index of refraction of the first and second cladding sections; and

b) different than a third index of refraction of the core section.

11. The battery structure of claim 10,

wherein the core section comprises a first plurality of pores which:

a) have a first pore size less than or equal to half the predetermined wavelength, and

b) have first pore spacing less than or equal to half the predetermined wavelength; and

wherein each of the first and second cladding sections comprises a respective second plurality of pores which;

a) have a second pore size less than or equal to half the predetermined wavelength, and

b) have second pore spacing less than or equal to half the predetermined wavelength.

12. A method for monitoring development of impending faults of a battery cell, the method comprising:

forming a battery cell separator between a first electrode and a second electrode having associated electrolyte, the battery cell separator formed of a light transmitting material that has light transmission characteristics that are a function of a state of impending faults of the battery cell;

wherein the battery cell separator comprises;

a core section,

a first cladding section between the core section and the first electrode, and

a second cladding section between the core section and the second electrode;

transmitting, using a light source in optical communication with a first edge of the battery cell separator, light, having a predetermined wavelength, into the battery cell separator; and

detecting, using a light detector in optical communication with a second edge of the battery cell separator, light transmitted through the battery cell separator,

wherein a fault state of a portion of the battery cell associated with the light detector can be determined based on the received light.

13. The method of claim 12, wherein a first index of refraction of the electrolyte is substantially equal to a second index of refraction of the core section and the first and second indices of refraction are not substantially equal to a third index of refraction of the first and second cladding sections.

14. The method of claim 13, wherein each of the first and second cladding sections comprises a plurality of pores which:

a) have a pore size less than or equal to half the predetermined wavelength; and

b) have pore spacing less than or equal to half the predetermined wavelength.

15. The method of claim 13, wherein the first index of refraction and the second index of refraction are between about 1.49 and 1.51, and the third index of refraction is about 1.46.

16. The method of claim 15, wherein the core section comprises polypropylene and each of the first and second cladding sections comprises porous glass.

17. The method of claim 12, wherein a first index of refraction of the electrolyte is substantially equal to a second index of refraction of the first and second cladding sections and the first and second indices of refraction are not substantially equal to a third index of refraction of the core section.

18. The method of claim 17, wherein the core section comprises a plurality of pores which:

a) have a pore size less than or equal to half the predetermined wavelength; and

b) have pore spacing less than or equal to half the predetermined wavelength.

19. The method of claim 17, wherein the first index of refraction and the second index of refraction are about 1.42, and the third index of refraction is about 1.46.

20. The method of claim 18, wherein:

a) the core section comprises porous glass;

b) the first cladding section comprises a first region between the core section and the first electrode containing a first portion of the electrolyte; and

c) the second cladding section comprises a second region between the core section and the second electrode containing a second portion of the electrolyte.

21. The method of claim 12, wherein a first index of refraction of the electrolyte is:

a) different than a second index of refraction of the cladding section; and

b) different than a third index of refraction of the core section.

22. The method of claim 21,

wherein the core section comprises a first plurality of pores which:

a) have a first pore size less than or equal to half the predetermined wavelength, and

b) have first pore spacing less than or equal to half the predetermined wavelength; and

wherein each of the first and second cladding sections comprises a respective second plurality of pores which;

a) have a second pore size less than or equal to half the predetermined wavelength, and

b) have second pore spacing less than or equal to half the predetermined wavelength.

23. A battery structure for monitoring development of impending faults of a battery cell, the battery structure comprising:

a first electrode and a second electrode;

a battery cell separator formed of a light transmitting material that has light scattering characteristics that are a function of a state of impending faults of the battery cell;

wherein the battery cell separator comprises;

a core section,

a first cladding section between the core section and the first electrode, and

a second cladding section between the core section and the second electrode;

an electrolyte capable of passing through portions of the battery cell separator;

a light source, in optical communication with the battery cell separator, for transmitting light, having a predetermined wavelength, into the battery cell separator; and

a light detector, in optical communication with the battery cell separator, for receiving light scattered within the battery cell separator,

wherein a fault state of a portion of the battery cell associated with the light detector can be determined based on the received light.

24. The battery structure of claim 23, wherein:

the light source is in optical communication with a first edge of the battery cell separator; and

the light detector is in optical communication with a second edge of the battery cell separator.

25. The battery structure of claim 23, wherein:

the light source is in optical communication with a first edge of the battery cell separator; and

the light detector is in optical communication with the first edge of the battery cell separator.