U.S. patent application number 09/997724 was filed with the patent office on 2003-01-09 for leak sensor for flowing electrolyte batteries.
Invention is credited to Tomazic, Gerd, Winter, Richard.
Application Number | 20030008204 09/997724 |
Document ID | / |
Family ID | 25411136 |
Filed Date | 2003-01-09 |
United States Patent
Application |
20030008204 |
Kind Code |
A1 |
Winter, Richard ; et
al. |
January 9, 2003 |
Leak sensor for flowing electrolyte batteries
Abstract
A leak detection system for a flowing electrolyte battery
comprises a manifold leak containment member associated with at
least one manifold which provides flowing electrolyte to at least
one stack of a flowing electrolyte battery and a provision for
sensing a fluid leak within the at least one manifold leak
containment member.
Inventors: |
Winter, Richard; (San Ramon,
CA) ; Tomazic, Gerd; (Murzzuschlag, AT) |
Correspondence
Address: |
FACTOR & PARTNERS, LLC
1327 W. WASHINGTON BLVD.
SUITE 5G/H
CHICAGO
IL
60607
US
|
Family ID: |
25411136 |
Appl. No.: |
09/997724 |
Filed: |
November 30, 2001 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
09997724 |
Nov 30, 2001 |
|
|
|
09899523 |
Jul 5, 2001 |
|
|
|
Current U.S.
Class: |
429/81 ;
429/61 |
Current CPC
Class: |
H01M 8/20 20130101; Y02E
60/10 20130101; G01M 3/186 20130101; Y10T 29/49108 20150115; H01M
10/365 20130101; H01M 8/188 20130101; H01M 10/4207 20130101; H01M
10/4228 20130101; Y02E 60/50 20130101; H01M 50/70 20210101; H01M
10/4214 20130101 |
Class at
Publication: |
429/81 ;
429/61 |
International
Class: |
H01M 002/38 |
Claims
What is claimed is:
1. A leak detection system for a flowing electrolyte battery
comprising: at least one manifold leak containment member
associated with at least one manifold which provides flowing
electrolyte to at least one stack of a flowing electrolyte battery;
and means for sensing a fluid leak within the at least one manifold
leak containment member.
2. The system of claim 1 wherein the sensing means comprises: at
least one switch comprising a first plate and a second plate,
wherein fluid within the containment member serves to electrically
couple the first plate to the second plate, to, in turn, close the
switch; a controller associated with the switch, the controller
capable of sensing the condition of the switch; and a connector
electrically associating the switch and the controller.
3. The system of claim 2 wherein the sensing means further
comprises: a resistor positioned in parallel to the switch.
4. The system of claim 2 wherein the at least one switch comprises
a plurality of switches positioned in parallel.
5. The system of claim 1 wherein the at least one manifold leak
containment member comprises a manifold leak containment member
associated with each manifold of the flowing electrolyte
battery.
6. A leak detection system for a flowing electrolyte battery
comprising: at least one containment member associated with at
least one manifold of a flowing electrolyte battery; at least one
containment member associated with at least one stack of a flowing
electrolyte battery; at least one containment member associated
with an electrolyte reservoir of a flowing electrolyte battery; and
means for sensing a fluid leak within one of the containment
members, wherein the sensing means comprises: at least one sensor
having at least one switch positioned within one of the containment
members such that a leak collecting in the respective containment
member triggers the switch; at least one controller associated with
the sensor; and a connector associated with each of the sensor and
controller.
7. The leak detection system of claim 6 wherein the sensor includes
a plurality of switches.
8. The leak detection system of claim 7 wherein the plurality of
switches are positioned substantially in parallel.
9. The leak detection system of claim 6 wherein the sensor includes
at least one resistor positioned in parallel with the at least one
switch.
10. The leak detection system of claim 6 wherein the controller
includes a means for signaling the condition of the sensor to a
user.
Description
CROSS REFERENCE TO PRIOR APPLICATION
[0001] This application is a continuation-in-part of application
Ser. No. 09/899,523 filed Jul. 5, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention is directed to flowing electrolyte batteries,
and in particular to a leak sensor for use in association with
flowing electrolyte batteries such as zinc/bromine batteries. It
will be understood that the application is not limited to any
zinc/bromine batteries or to any other particular flowing
electrolyte battery.
[0004] 2. Background Art
[0005] Flowing electrolyte batteries (Zn--Br batteries, V-Redox
batteries, etc) are well known in the art for their quality of
power providing characteristics and their cycling ability.
Generally, such batteries rely on the circulation, by pumps, of
electrolyte. As the circulation of electrolyte includes a multitude
of components, fittings and conduit, a potential always exists for
failure of one of these components. Such failure will generally
result in a leak of electrolyte.
[0006] In addition, since many such batteries require cooling
systems which likewise comprise a multitude of conduit, fittings
and component, the cooling systems are likewise problematic.
Failure in such components generally results in a leak of coolant.
Further still, many such batteries, especially in industrial
applications, are placed in a substantially sealed container which
remains exposed to a harsh environments. As such, damage to the
sealed container often results in the collection of precipitation
within the container.
[0007] Any leak of electrolyte or coolant, as well as any entry of
outside moisture can have catastrophic results. Specifically, not
only will it cause the battery to operate in a less than optimal
condition, the battery may completely fail. For industrial
applications, and especially when used as an emergency power
supply, such batteries must be ready for immediate operation. If a
battery fails, then it is incapable of providing power in an
emergency. Thus, it is important to provide early notification of a
leak in such a battery.
[0008] Moreover, in the event of a failure, it is important to
contain any leaks, thereby precluding contamination of the battery
by the leaking fluid. By limiting the contamination caused by the
fluid leak, the battery can be more easily repaired and returned to
operation.
[0009] Furthermore, by limiting the contamination caused by the
fluid leak to the specific location of leakage within a multitude
of components, fittings and conduit, the battery can be repaired
even more rapidly and efficiently.
[0010] Thus, it is an object of the invention to facilitate the
containment of a leak within a flowing electrolyte battery.
[0011] It is another object of the invention to facilitate the
detection of a leak of fluid within a flowing electrolyte battery.
It is a further object of the invention to facilitate the detection
of a leak of fluid within a flowing electrolyte battery at the
precise location of leakage within a multitude of components,
fittings and conduit.
SUMMARY OF THE INVENTION
[0012] The invention comprises a leak detection system for a
flowing electrolyte battery. In particular, the system comprises at
least one manifold leak containment member associated with at least
one manifold which provides flowing electrolyte to at least one
stack of a flowing electrolyte battery and means for sensing a
fluid leak within the at least one manifold leak containment
member.
[0013] In one embodiment, the sensing means comprises a switch, a
controller and a connector. The switch comprises a first plate and
a second plate, wherein fluid within the containment member serves
to electrically couple the first plate to the second plate, to, in
turn, close the switch. The controller is associated with the
switch and is capable of sensing the condition of the switch. The
connector electrically associates the switch and the
controller.
[0014] In another embodiment, the sensing means further comprises a
resistor positioned in parallel to the switch.
[0015] In yet another embodiment, the at least one switch comprises
a plurality of switches positioned in parallel.
[0016] Preferably, the at least one manifold leak containment
member comprises a manifold leak containment member associated with
each manifold of the flowing electrolyte battery.
[0017] In another aspect of the invention, the invention comprises
a leak detection system for a flowing electrolyte battery
comprising at least one containment member associated each of at
least one manifold of a flowing electrolyte battery, at least one
stack of a flowing electrolyte battery; and an electrolyte
reservoir of a flowing electrolyte battery, as well as, means for
sensing a fluid leak within one of the containment members.
[0018] The sensing means in such an embodiment comprises at least
one sensor having at least one switch positioned within one of the
containment members such that a leak collecting in the respective
containment member triggers the switch, at least one controller
associated with the sensor, and, a connector associated with each
of the sensor and controller.
[0019] In one embodiment, the sensor includes a plurality of
switches. In one such embodiment, the plurality of switches are
positioned substantially in parallel.
[0020] In another embodiment of the invention, the sensor includes
at least one resistor positioned in parallel with the at least one
switch.
[0021] In yet another embodiment of the invention, the controller
includes a means for signaling the condition of the sensor to a
user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 of the drawings is a schematic representation of the
present invention;
[0023] FIG. 2 of the drawings is a schematic representation of the
manifold and manifold leak containment member of the present
invention;
[0024] FIG. 3 of the drawings is a schematic representation of a
side view of the manifold leak containment member of the present
invention;
[0025] FIG. 4 of the drawings is a schematic representation of a
top view of the manifold leak containment member of the present
invention;
[0026] FIG. 5 of the drawings is a schematic representation of the
sensor of the present invention;
[0027] FIG. 6 of the drawings is a schematic representation of
multiple sensors of the present invention; and
[0028] FIG. 7 of the drawings is a schematic representation of a
second embodiment of a sensor of the present invention.
BEST MODE FOR PRACTICING THE INVENTION
[0029] While this invention is susceptible of embodiment in many
different forms, there is shown in the drawings and will be
described in detail, one specific embodiment with the understanding
that the present disclosure is to be considered as an
exemplification of the principles of the invention and is not
intended to limit the invention to the embodiment illustrated.
[0030] Leak detection system 10 is shown in FIG. 1 as comprising
manifold leak containment member 11, stack leak containment member
12, electrolyte containment member 14 and means 16 for sensing a
leak. Leak detection system 10 is for use in association with a
flowing electrolyte battery, such as zinc/bromine battery 100.
While various flowing electrolyte batteries are contemplated for
use, the invention will be described with reference to a
zinc/bromine battery solely as an example.
[0031] Generally, zinc/bromine battery 100 includes one or more
stacks, such as stack 102, electrolyte reservoir 104, circulating
means 106 and means 108 for controlling the climate within battery
100. Stack 102 includes a plurality of arranged anodes and cathodes
so as to comprise a plurality of stacked cells. Electrolyte
reservoir 104 stores the electrolyte which is circulated by
circulation means 106 through stack 102. In certain embodiments, a
climate control means 108 may be incorporated to either heat or
cool the electrolyte so as to maintain the overall battery within
operating parameters.
[0032] As shown in FIGS. 1 and 2, each stack 102 includes a
plurality of manifolds, such as manifolds 110, 111 associated
therewith. Each such manifold 110, 111 includes a base 112 and
openings, such as openings 135. Base 112 includes recess 85.
Manifold 110 receives electrolyte from reservoir 104 via
circulating means 106 and directs electrolyte through openings 135
to the arranged anodes and cathodes of stack 102 via a plurality of
manifold circulating means 84. Manifold 111 receives electrolyte
that has traveled through stack 102 and facilitates the return of
the electrolyte that has passed across the anodes and cathodes,
ultimately, to reservoir 104. Each of the manifolds, such as
manifolds 110, 111, can be of any appropriate size and geometric
configuration so as to be consistent with the size and
configuration of stack 102. Additionally, while two manifolds are
shown, each stack may include a greater number of manifolds. In
certain embodiments, the supply of electrolyte can enter into
manifold through a bore that is made in recess 85.
[0033] As shown in FIGS. 2-4, manifold leak containment member 11
includes base 89 and sides 90, 91 which define cavity 86. Each
manifold leak containment member 11 includes a protrusion 87.
Protrusion 87 is configured in with a complementary geometry to
recess 85 so as to facilitate alignment with and proper positioning
of base 112 of the respective manifold within cavity 86 of the
manifold containment member. In certain embodiments, the
electrolyte feed tube for the manifold extends through protrusion
87 and recess 85. As will be explained in detail below, manifold
leak containment member 11 is positioned as described so as to
receive and contain any leaks that may occur in manifold 110 or in
any component attached thereto. Preferably, each manifold leak
containment member comprises a molded plastic member which is
substantially non-reactive with the fluid electrolyte material.
[0034] Electrolyte stack containment member 12 is shown in FIG. 1
as comprising base 30 and sides 32 which define cavity 34. As will
be understood at least a portion of stack 102 is positioned within
cavity 34 such that, in the case of an electrolyte leak in stack
102, such a leak will fill cavity 34. In embodiments such as the
embodiment shown in FIG. 1, wherein two vertically oriented stacks
102, 102' form a tower, each stack has its own electrolyte
containment member, 12, 12'. In such an embodiment, the upper
electrolyte containment member 12 includes overflow opening 36,
which, in turn, directs any overflow of electrolyte into the
electrolyte containment member 12'. In this manner, the spread of
electrolyte can be minimized.
[0035] Reservoir leak containment member 14 is shown in FIG. 1 as
comprising base 40 and sides 42 which define cavity 44. The
electrolyte reservoirs are positioned within the reservoir
containment member such that any leak in the electrolyte reservoirs
will be contained by the reservoir containment member. In addition,
the reservoirs, and, in turn, the reservoir containment members are
positioned below stack 102 such that, in the event of a leak which
overflows electrolyte stack containment member 12 (or 12') will be
directed into, and contained by, reservoir containment member
14.
[0036] Sensing means 16 is shown in FIG. 1 as comprising sensors,
such as sensor 50, controller 52 and connector 54. As will be
explained, sensors 50 are preferably present both at base 30 of
stack leak containment member 12 and within cavity 86 of manifold
leak containment member 11. Each such sensor 50 includes base
resistor 60 and switch 62. Switch 62 is in parallel with resistor
60 and includes surface 70 and surface 72. As will be explained in
detail below, in the event of a leak, the leaking fluid contacts
surface 70 and surface 72, to, in turn, close the circuit,
essentially forming a switch. While other shapes are contemplated,
the surfaces 70, 72 comprise mesh surfaces. Such mesh surfaces
provide a relatively large surface area for contact of the fluid
with the mesh surfaces. While various systems are contemplated,
resistor 60 comprises a resistor having a value of 3000.OMEGA., and
the voltage applied to switch 62 and resistor 60 is 24V. Of course,
various other circuits are contemplated, wherein the applied
voltage may be either lower or higher, and, various resistors are
contemplated for use. In other embodiments, the resistor may be
omitted wherein the controller views the circuit as an open circuit
until such time as the switch is closed.
[0037] Connector 54 connects controller 52 to sensor 50 such that
controller 52 is capable of sensing the closing of a switch 62 of
sensor 50. As will be explained below, if fluid from a leak
provides a closed circuit across surfaces 70, 72, then the
resistance of the parallel combination of the switch and the
resistor effectively decreases, and the current in the system
increases (i.e. voltage remains constant, and therefore voltage is
equal to resistance times current). Controller 52 comprises a
digital microcontroller capable of reading the current change
across the resistor and the switch. Of course, various analog or
digital systems are contemplated for use.
[0038] In operation, a flowing electrolyte battery is first
equipped with leak detection system 10. Specifically, manifold leak
containment member 11 is provided for each manifold 110, 111, stack
leak containment member 12 is provided for each stack and each
stack is positioned so that a portion is within cavity 34.
Additionally, electrolyte reservoirs 104 are positioned within
electrolyte reservoir leak containment member 14.
[0039] Once the containment members are positioned, sensors 50 are
positioned within the cavity 86 of each manifold leak containment
member 11 and within each stack leak containment member 12.
Subsequently, sensors, such as sensor 50, are likewise positioned
within the reservoir leak containment member 14, and likewise in
the bottom of the unit (in case of overflow from any of the
containment members). Once positioned, each sensor is attached to
one or more controllers, such as controller 52, via connectors 54.
The sensors are positioned such that a leak that collects in any of
the respective containment members (or at the bottom of the unit)
will close a circuit about the surfaces 70, 72 of the respective
switch 62, which can be sensed by controller 52. Generally, to
achieve early recognition of leaks, the sensors are generally
positioned proximate the lowest point of the respective containment
member.
[0040] From time to time, the flowing electrolyte battery can
experience an electrolyte leak in, for example manifold 110. In
such an instance, the electrolyte leak will collect in the
respective manifold leak containment member 11 . As the level of
electrolyte in the manifold leak containment member 11 increases,
eventually, electrolyte will contact both surface 70 and surface 72
of switch 62, thereby effectively closing the circuit. As a result,
the current in the circuit will tend to increase, and the increase
is sensed by controller 50. Controller 50 can then provide some
type of final output (i.e. audible, visual, radio, infra red,
connection to a main control unit, etc.) so that a user can be
informed of the leak. In certain embodiments, the electrolyte pumps
can automatically be turned off upon recognition of a leak.
[0041] Similarly, a leak in the reservoir 104 will tend to cause
electrolyte to enter into the reservoir containment member 14. As
the level of electrolyte increases in the reservoir leak
containment member 14, electrolyte will contact surface 70 and 72
of the sensor positioned within the reservoir leak containment
member and the switch will be effectively closed by the
electrolyte. In turn, the circuit will exhibit an increased current
which will be sensed by the controller 50.
[0042] It will be understood that in certain embodiments which
utilize a liquid coolant, a coolant leak can occur. Such a coolant
leak will generally collect in the base of the unit or in the
reservoir containment member. As with the electrolyte leak, as the
coolant level rises, the coolant will contact the surfaces 70 and
72 of one of the sensors, thereby effectively closing the
switch.
[0043] Again, the controller will recognize the closing of the
switch. Indeed, any fluid collection (i.e. electrolyte leak,
coolant leak, condensation, outside precipitation) within any of
the containment members or proximate the base of the flowing
electrolyte battery will trigger a sensor switch to close. Since
each such fluid generally comprises a different resistivity (i.e.
the electrolyte is generally exhibits less electrical resistance
than coolant or water(contaminated)), current changes sensed by the
controller will be different based on the fluid that is causing the
closing of the respective switch. In turn, the controller can be
programmed to distinguish between the different leaks. In this
case, if the controller determines that the cause of the leak is
condensation, there is no need to service the battery or to take
the battery out of operation.
[0044] In another embodiment, as shown in FIG. 6, the sensor may
comprise a plurality of switches in parallel with a single
resistor. In such an embodiment, each switch may be positioned in a
different area, such as the electrolyte containment member, the
electrolyte reservoir containment member and the overflow area of
the housing. As such, a leak in any one of these areas will cause
fluid in the respective area to close the switch, and in turn,
lower the overall resistance of the circuit. The lower resistance
(and increased current) is then sensed by the controller which is
attached to the sensor. In such an embodiment, the controller can
signal a leak, however, the precise location of the leak is not
known.
[0045] In another embodiment, as shown in FIG. 7 , sensor 50 may
include an additional switch, namely, switch 63 which is positioned
in parallel to switch 62 and resistor 60. When installed, switch 63
is positioned lower than switch 62 such that a leak will first
close switch 63 before the leak closes switch 62. As will be
understood, a small leak will tend to close switch 62, whereas a
large leak will tend to close switch 63 and switch 62. As a result,
the controller will receive a first current reading increase as the
leak closes switch 63 and a second current reading increase as the
leak closes switch 62. Accordingly, the controller can be used to
access the severity of the leak, as well as the precise origin of
the leak, such as from the manifold or the stack.
[0046] The foregoing description merely explains and illustrates
the invention and the invention is not limited thereto except
insofar as the appended claims are so limited, as those skilled in
the art who have the disclosure before them will be able to make
modifications without departing from the scope of the
invention.
* * * * *