Sensor could help prevent Li-ion battery fires
In a new study published in ACS Applied Materials & Interfaces, researchers have developed a sensor that can detect dangerous gas leaks in lithium-ion batteries.
“Lithium-ion batteries are everywhere,” said Liangdan Zhao, lead author of the study. “They power everything from smartphones and laptops to electric vehicles, military applications and beyond. While they offer high energy density and a long lifespan, they also come with large safety risks.”
When battery cells overheat or are damaged, volatile electrolyte vapours can be released and may ignite, triggering fires or explosions. Consequently, there is an urgent need to develop gas sensors that are not only highly sensitive and selective but also low-cost, easily integrated and energy-efficient.
“Our research is motivated by this critical safety challenge,” Zhao said. “By focusing on the early detection of electrolyte leakage, we aim to contribute to safer battery management systems, potentially preventing catastrophic failures and enhancing the overall reliability of lithium-ion battery-powered technologies.”
Early detection of gas leaks
The new sensor detects trace amounts of ethylene carbonate (EC) vapour — a key component of a battery’s electrolyte — that can flag potential battery failures before they escalate into disasters.
The researchers developed the highly sensitive and cost-effective gas sensor using covalent organic frameworks (COFs), molecular structures that can be engineered to selectively detect specific gases. This is the first time the computationally guided design of a COF-based sensor has been used specifically for EC detection.
“We screened hundreds of potential materials using computational methods before identifying COF-QA-4 as the best candidate,” Zhao said. “It’s highly sensitive and selective, targeting the harmful EC gas while ignoring other vapours. The sensor can detect leaks long before they become hazardous.”
The sensor has shown remarkable performance in laboratory tests, being capable of detecting EC vapour at concentrations as low as 1.15 parts per million (ppm).
Enhancing safety across industries
The researchers say the sensor’s potential impact extends far beyond electric vehicles. It could also be integrated into battery management systems across smart home devices and industrial safety systems, providing real-time alerts for hazardous gas leaks and offering an early warning system that could prevent catastrophic accidents.
“By incorporating this sensor into existing systems, manufacturers can take proactive measures to avoid dangerous situations,” Zhao said. “This could save lives and protect property by detecting potential failures long before they escalate.”
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