Battery Cell Wear Sensor Visual Appearance Change
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Solution Overview
Problem
Conventional methods for detecting worn-out battery cells in high-performance battery modules and packs are inefficient, costly, and pose safety risks, as they often require disassembly and electrical testing, which is not time-efficient and can miss dry-out cells or provide insufficient overheating information.
Innovation Solution
A battery cell design with integrated wear sensors that change visual appearance based on measured parameters, allowing for non-invasive visual inspection of wear states, and a battery management system using optical sensors to detect these changes, enabling easy and cost-effective sorting and diagnosis of battery conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional electrical testing methods are used to detect worn-out battery cells, then measurement precision may be improved, but device complexity and loss of time increase due to required disassembly and sophisticated testing procedures
Solution Approach 1:
The wear sensor performs preliminary detection of wear parameters (electrolyte leakage, dry-out, overheating) continuously during battery operation, so that when inspection is needed, the battery management system already has pre-collected data about the cell's condition, eliminating the need for time-consuming disassembly and electrical testing
Solution Approach 2:
The patent replaces mechanical/electrical testing methods with an optical detection system. The wear sensor changes its optical properties (color, transparency) based on wear parameters, and the battery management system uses optical sensors to detect these changes, substituting complex electrical testing with simple optical inspection
2Reliability
If battery modules are fully encapsulated for protection, then reliability and protection are improved, but ease of operation deteriorates as inspection and replacement become difficult
Solution Approach 1:
The battery cell performs self-diagnosis through the wear sensor that continuously monitors its own wear parameters (electrolyte leakage, dry-out, overheating) and communicates this information optically to the battery management system, eliminating the need for external disassembly and complex electrical testing procedures
Solution Approach 2:
The wear sensor changes its visual appearance (color, transparency) in response to wear parameters, allowing service personnel to quickly assess battery cell condition through simple visual inspection without disassembling the encapsulated battery module
3Measurement precision
If sophisticated electrical tests are performed for battery sorting, then measurement precision is improved, but productivity decreases due to high costs and safety risks
Solution Approach 1:
The patent replaces sophisticated electrical testing with optical detection. The wear sensor's optical properties change in response to wear parameters, and the battery management system uses optical sensors to detect these changes, providing accurate battery sorting information without the high costs and safety risks of electrical testing
Solution Approach 2:
The wear sensor creates an optical copy or representation of the battery cell's internal condition (electrolyte leakage, dry-out, overheating) that can be read externally by the battery management system, allowing accurate sorting without direct electrical contact or complex testing procedures
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables fast, safe, and cost-efficient sorting and diagnosis of battery wear without disassembly, improving battery safety and reliability by providing a visual diagnostic tool for service engineers to assess State Of Health (SOH) and detect issues like leakage, swelling, and overcharging.
Implementation Method 1
the wear sensor is configured for determining at least one wear parameter and for changing its visual appearance depending on the measured wear parameter
Data Source
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AI summary
A battery cell (20) is provided. The battery cell (20) comprises a cell body (21); at least two electrical contacts (30, 32); and at least one wear sensor (42) being arranged within and/or at the cell body (21) such that it is visible from outside of the cell body (21) and being configured for determining at least one wear parameter and for changing its visual appearance depending on the measured wear parameter.