System for detecting electrolyte leaks during battery manufacturing

Patent metadata

Field	Value
Publication number	US-12525657-B2
Application number	US-202318112552-A
Country	US
Kind code	B2
Filing date	Feb 22, 2023
Priority date	Feb 22, 2023
Publication date	Jan 13, 2026
Grant date	Jan 13, 2026

Abstract

A method for testing a battery component for leakage includes generating a sample from a battery component storing electrolyte using a Fourier Transform infrared (FT-IR) spectrometer, comparing absorbance levels of the sample at N predetermined frequencies to N predetermined thresholds, respectively, where N is an integer greater than one; and selectively detecting at least one of an electrolyte leak and generating an electrolyte concentration estimate in response to the comparison. The battery component is selected from a group consisting of a battery cell, a battery module, and a battery pack.

First claim

What is claimed is:

1 . A method for testing a battery component for leakage, comprising:
arranging a battery component storing electrolyte in an enclosure; drawing vacuum pressure in the enclosure; generating a first sample from a battery component storing electrolyte using a total volatile organic compound (VOC) sensor, wherein the first sample is generated at vacuum pressure; comparing an output of the total VOC sensor to a predetermined threshold; completing testing of the battery component without using a Fourier Transform infrared (FT-IR) spectrometer in response to the output of the total VOC sensor being less than the predetermined threshold; generating a second sample from the battery component storing electrolyte using a Fourier Transform infrared (FT-IR) spectrometer only in response to the output of the total VOC sensor being greater than the predetermined threshold, wherein the second sample is generated at vacuum pressure; comparing absorbance levels of the second sample at N predetermined frequencies to N predetermined thresholds, respectively, where N is an integer greater than one; and selectively detecting an electrolyte leak and generating an electrolyte concentration estimate in response to the comparison, wherein the battery component is selected from a group consisting of a battery cell, a battery module, and a battery pack.

2 . The method of claim 1 , further comprising performing an electrical test of the battery component prior to generating the first sample.

3 . The method of claim 2 , wherein the electrical test of the battery component comprises at least one of charging and discharging of the battery component.

4 . The method of claim 1 , further comprising using at least one of a thermal interface of the battery component and an external heater to heat the battery component prior to generating the first sample.

5 . The method of claim 1 , further comprising using a tube to generate the first sample from a predetermined location of the battery component.

6 . The method of claim 1 , wherein the battery component comprises a battery cell, and further comprising generating the first sample after trimming external tabs of the battery cell using a laser.

7 . The method of claim 1 , wherein N is equal to 3.

8 . The method of claim 1 , further comprising performing at least one of a principal component analysis and a chemometric analysis on the first sample and selectively detecting the electrolyte leak in response to the at least one of the principal component analysis and the chemometric analysis.

9 . The method of claim 1 , further comprising performing a principal component analysis on an entire spectral range of the second sample to determine a relationship between a first principal component and electrolyte concentration, wherein spectral regions that absorb due to the electrolyte leak have higher absorbance values than spectral regions without sensed electrolyte present.

10 . The method of claim 1 , further comprising performing a chemometric analysis on the second sample to limit false positives from environmental factors, wherein the chemometric analysis includes co-monitoring water vapor and carbon dioxide levels and controlling for water vapor and carbon dioxide levels in an infrared spectrum.

11 . A method for testing a battery component for leakage, comprising:
arranging a battery component storing electrolyte in an enclosure; drawing vacuum pressure in the enclosure; generating a first sample from a battery component storing electrolyte using a total volatile organic compound (VOC) sensor, wherein the first sample is generated at vacuum pressure; comparing an output of the total VOC sensor to a predetermined threshold; completing testing of the battery component without using a Fourier Transform infrared (FT-IR) spectrometer in response to the output of the total VOC sensor being less than the predetermined threshold; generating a second sample from the battery component using a Fourier-Transform infrared (FTIR) spectrometer only in response to the output of the total VOC sensor being greater than the predetermined threshold, wherein the second sample is generated at vacuum pressure; and selectively detecting an electrolyte leak in response to the second sample from the FTIR spectrometer, wherein the battery component is selected from a group consisting of a battery cell, a battery module, and a battery pack.

12 . The method of claim 11 , further comprising comparing absorbance levels of the second sample at N predetermined frequencies to predetermined thresholds, where N is an integer greater than one.

13 . The method of claim 11 , further comprising performing at least one of a principal component analysis and a chemometric analysis on the second sample and selectively detecting the electrolyte leak in response to the at least one of the principal component analysis and the chemometric analysis.

14 . The method of claim 11 , further comprising performing an electrical test of the battery component prior to generating the second sample.

15 . The method of claim 14 , wherein the electrical test of the battery component comprises at least one of charging and discharging of the battery component.

16 . The method of claim 11 , further comprising using at least one of a thermal interface of the battery component and an external heater to heat the battery component prior to generating the second sample.

17 . The method of claim 11 , further comprising using a tube to generate the second sample from a predetermined location of the battery component.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Sekol Ryan Curtis
• Salvador James R
• Wiebenga Michelle H
• Collin William Reginald
• Brady Christopher
• Dietze Jr Robert H
• Bracey Jennifer Therese
• Yang Houssen

Classifications

• G01N21/71

  thermally excited · CPC title

• H01M10/48

  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 title

• G01N21/25

  Colour; Spectral properties, i.e. comparison of effect of material on the light at two or more different wavelengths or wavelength bands · CPC title

• H01M10/44

  Methods for charging or discharging (circuits for charging H02J7/00) · CPC title

• G01M3/04 Primary

  by detecting the presence of fluid at the leakage point · CPC title