Editorial Feature

Battery Leak Detection: How Sensors Can Help

Batteries are ubiquitous in our daily lives, powering everything from our smartphones to our cars. However, they can also pose a safety risk if they leak or overheat. Battery leaks can cause damage to devices and can be a fire hazard if they come into contact with flammable materials.

Battery Leak Detection: How Sensors Can Help

Image Credit: BigNazik/Shutterstock.com

The Problem with Battery Leaks

Battery leaks occur when the battery casing is compromised, allowing the electrolyte to leak out. This can happen for several reasons, such as physical damage to the battery or a manufacturing defect.

The electrolyte is a mixture of chemicals that can be corrosive and flammable, making it dangerous if it comes into contact with skin or flammable materials.

The effects of battery leaks can be devastating, both in terms of financial loss and potential harm to people.

Notably, in 2016, the Samsung Galaxy Note 7 was recalled due to battery issues that caused the phone to catch fire. In addition, in 2019, a Tesla Model S caught fire after hitting a tow truck due to a battery leak.

Detecting Battery Leaks

Detecting battery leaks early can prevent damage to devices and reduce the risk of fire hazards. One way to detect battery leaks is through the use of sensors. These sensors can be integrated into batteries to monitor leaks and other potential issues.

There are several types of sensors that can be used to detect battery leaks, including acoustic sensors, optical sensors, and electrochemical sensors.

Acoustic sensors can detect battery leaks by listening to the sound of the electrolyte leaking out of the battery. When the electrolyte leaks, it can create a hissing or cracking sound that can be detected by an acoustic sensor.

These sensors are particularly effective for detecting leaks in large batteries, such as those used in electric cars.

Optical sensors use light to detect battery leaks. When the electrolyte leaks out of the battery, it can cause a change in the color of the battery casing. Optical sensors can detect this color change and alert the user to the leak. These sensors are particularly effective for detecting leaks in small batteries, such as those used in smartphones.

Electrochemical sensors can detect battery leaks by measuring changes in the electrolyte. When the electrolyte leaks out of the battery, it can change the pH level and conductivity of the surrounding area.

Electrochemical sensors can detect these changes and alert the user to the leak. These sensors are particularly effective for detecting leaks in batteries with high energy densities, such as those used in electric cars.

Challenges with Battery Leak Detection

While sensors can be effective for detecting battery leaks, there are still some challenges to overcome.

One of the biggest challenges is the cost of integrating sensors into batteries. Battery manufacturers are under pressure to reduce costs and increase energy density, making it difficult to justify the additional cost of integrating sensors.

In addition, some types of sensors may be more effective for detecting leaks in certain batteries. For instance, acoustic sensors may be more effective for large batteries, while optical sensors may be more effective for small batteries.

As a result, battery manufacturers may need to use multiple types of sensors to detect leaks in their products.

Another challenge is the need for regular maintenance and calibration of sensors. Sensors can become less effective over time and may require calibration to ensure accurate readings.

For devices that are designed to be used for long periods of time without maintenance, this might pose a challenge.

Battery Leak Detection – A Global Endeavor

There are several organizations that are working on developing and improving battery leak detection systems using sensors.

The National Renewable Energy Laboratory (NREL) is a U.S. government-funded laboratory focusing on developing and advancing energy technologies, including battery technologies. The organization is developing acoustic and optical sensors that detect battery leaks in real-time.

The Fraunhofer Institute for Silicon Technology (ISIT) is a German research organization working on developing a new type of electrochemical sensor that can detect battery leaks in real-time.

UL LLC is a global safety certification company that works on developing standards and testing for a wide range of products and technologies, including batteries. The organization is developing standards for battery leak detection systems to ensure they are safe and effective.

These organizations are working on developing and improving battery leak detection systems using different types of sensors and technologies. Collaboration and cooperation between these organizations can help advance the technology further and improve battery safety.

To Conclude

Battery leaks can be a serious safety risk, but using sensors can help detect leaks early and prevent potential disasters.

There are several types of sensors that can be used to detect battery leaks, including acoustic, optical, and electrochemical sensors.

While these sensors have shown promise, there are still challenges to overcome, such as the cost of integrating sensors and the need for regular maintenance and calibration.

Developing more effective and affordable sensors will help improve battery safety and reduce the risk of incidents such as fires and explosions.

As technology continues to advance, we can expect to see more innovative solutions for detecting battery leaks and improving battery safety.

Continue reading: Electric Vehicle Sensors for Leak Detection

References and Further Reading

Lu, Y., Zhang, S. et al. (2020). Ultrasensitive Detection of Electrolyte Leakage from Lithium-Ion Batteries by Ionically Conductive Metal-Organic Frameworks. Matter, 3(3), pp. 904-919. https://doi.org/10.1016/j.matt.2020.05.021

Mateev, V., Marinova, I., & Kartunov, Z. (2019). Gas Leakage Source Detection for Li-Ion Batteries by Distributed Sensor Array. Sensors. doi.org/10.3390/s19132900

Newcomb, A. (2017). Samsung Finally Explains the Galaxy Note 7 Exploding Battery Mess. Retrieved from NBC News: Available at: https://www.nbcnews.com/tech/tech-news/samsung-finally-explains-galaxy-note-7-exploding-battery-mess-n710581

Wenger, M., Waller, R., Lorentz, V. R., März, M., & Herold, M. (2014). Investigation of gas sensing in large lithium-ion battery systems for early fault detection and safety improvement. IECON 2014 - 40th Annual Conference of the IEEE Industrial Electronics Society. doi.org/10.1109/IECON.2014.7049366

Disclaimer: The views expressed here are those of the author expressed in their private capacity and do not necessarily represent the views of AZoM.com Limited T/A AZoNetwork the owner and operator of this website. This disclaimer forms part of the Terms and conditions of use of this website.

Shaheer Rehan

Written by

Shaheer Rehan

Shaheer is a graduate of Aerospace Engineering from the Institute of Space Technology, Islamabad. He has carried out research on a wide range of subjects including Aerospace Instruments and Sensors, Computational Dynamics, Aerospace Structures and Materials, Optimization Techniques, Robotics, and Clean Energy. He has been working as a freelance consultant in Aerospace Engineering for the past year. Technical Writing has always been a strong suit of Shaheer's. He has excelled at whatever he has attempted, from winning accolades on the international stage in match competitions to winning local writing competitions. Shaheer loves cars. From following Formula 1 and reading up on automotive journalism to racing in go-karts himself, his life revolves around cars. He is passionate about his sports and makes sure to always spare time for them. Squash, football, cricket, tennis, and racing are the hobbies he loves to spend his time in.

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