Insights from Honeywell Expert on Vapor Detection for Batteries

As battery technology becomes more integral to industries ranging from electric vehicles (EVs) to energy storage systems (ESS), ensuring the safety and reliability of these systems has become increasingly critical. One emerging solution is the detection of battery electrolyte vapor—a breakthrough technology that provides early warning of potential battery failures, preventing hazardous incidents like thermal runaway. In this Q&A, Nirmal A Kumar, Sr. Field Application Engineer at Honeywell, discusses the latest advancements in electrolyte vapor detection, its role in improving battery health monitoring, and its impact across various industries, from cell manufacturing to recycling.

How does the detection of battery electrolyte vapor contribute to overall battery safety and reliability beyond electric vehicles?

Honeywell Sr. Field Application Engineer Nirmal A Kumar: Electrolyte vapor detection significantly improves safety and reliability across applications beyond EVs. In cell manufacturing, it identifies leaks early, ensuring only defect-free cells are used preventing faulty batteries from entering the market. During cell transportation, the detection system monitors electrolyte leaks that could result from physical stress, preventing dangerous incidents like thermal runaway. In battery assembly, vapor detection helps remove compromised cells before integration, improving the reliability of battery packs in EVs, ESS, and industrial applications. In recycling, detecting vapor helps identify leaks in damaged cells, ensuring safe handling and reducing the risk of fires. This technology is also vital for off-road vehicles and two-wheelers/three-wheelers (2W/3W), where rugged conditions and vibrations can cause leaks, and for energy storage systems, ensuring long-term stability and safety.

Related:How Leak Testing is Adapting to EV Battery Manufacturing

Honeywell Sr. Field Application Engineer Nirmal A Kumar. Courtesy of the Battery Show North America.

What advancements in sensor technology have enabled more accurate and reliable detection of electrolyte vapors?

Kumar: Recent sensor technology advancements have enhanced the accuracy and reliability of electrolyte vapor detection. These sensors now offer high sensitivity and selectivity to common Li-ion battery electrolytes, ensuring leaks are detected early, even at low concentrations. They are resistant to siloxanes, which are environmental contaminants that could degrade sensor performance in industrial settings. Additionally, these sensors require no calibration after installation, significantly reducing maintenance costs and improving reliability over time. Their long service life of ~10 years further increases their utility across various applications.

Related:Li-ion Electrolyte Leak Testing Speeds Up

How does this new technology align with and support emerging global safety regulations for battery systems?

Kumar: This new sensing technology aligns with global safety regulations such as UN Global Technical Regulations (GTR) for EVs and China’s Guobiao (GB) standards for battery systems. These regulations emphasize the importance of early detection of battery failures, including electrolyte leaks and thermal runaway events. The sensor’s ability to detect electrolyte vapor before a catastrophic failure enables battery manufacturers and users to comply with stringent safety requirements, providing an essential early warning system. The sensors are compact, adaptable, and available in multiple formats, allowing them to easily integrate into new or existing battery systems across various industries. This technology supports the global push for safer and more reliable energy storage solutions by offering a proactive approach to battery safety.

What other potential applications or industries can benefit from this electrolyte vapor detection technology?

Kumar: Beyond EVs, this electrolyte vapor detection technology can significantly benefit industries such as ESS used in wind and solar farms, where the safety and stability of large battery installations are critical. It can also be applied to off-road vehicles and 2W/3W, where harsh environmental conditions increase the likelihood of battery leaks. In cell manufacturing, transportation, and assembly, this technology ensures that any leaks or issues are detected early, improving product quality and safety. Additionally, battery recycling facilities can use this technology to safely handle damaged or aged cells, preventing fires or hazardous chemical releases during the disassembly process. The technology's versatility and adaptability make it suitable for a wide range of battery-powered applications in both industrial and commercial sectors.

Editor’s Note: Nirmal A Kumar, Sr. Field Application Engineer at Honeywell, will be present at the Battery Show North America, where he will discuss "A Breakthrough in Battery Safety: The Detection of Battery Electrolyte Vapor for Battery Health Monitoring."