Early Detection of Failing Automotive Batteries Using Gas Sensors

Safety for automotive lithium-ion battery (LIB) applications is of crucial importance, especially for electric vehicle applications using batteries with high capacity and high energy density. In case of a defect inside or outside the cell, serious safety risks are possible including extensive heat generation, toxic and flammable gas generation, and consequently fire and explosion. New regulations (GB 38031-2020) require a warning for passengers at least five minutes before serious incidents. This regulation can hardly be fulfilled with state-of-the-art battery monitoring. In this study, gases produced during battery failure before and during a thermal runaway (TR) are investigated in detail and the use of different gas sensors as early detectors of battery incidents is tested and proposed. The response of several commercially available gas sensors is tested in four battery failure cases: unwanted electrolysis of voltage carrying parts, electrolyte vapor, first venting of the cell and the TR. The experiments show that battery failure detection with gas sensors is possible but depends highly on the failure case. The chosen gas sensor can detect H-2 produced by unwanted electrolysis and electrolyte vapor and gases produced by degassing of state-of-the-art LIBs. The results may contribute significantly to failure detection and improvement of battery safety.

Automated summary

The study investigated gases produced during battery failure, before and during thermal runaway, and tested different gas sensors as early detectors of battery incidents. Several commercially available gas sensors were tested in four battery failure cases, showing that gas sensors can detect battery failures depending on the specific case. The chosen gas sensor was able to detect hydrogen from unwanted electrolysis, electrolyte vapor, and gases released from state-of-the-art LIBs, contributing significantly to improving battery safety.