Battery Pack Swelling Gauge for Visual Deformation Monitoring
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Solution Overview
Problem
Battery packs experience swelling due to high temperatures during repeated charging and discharging, which can damage their appearance and stability, and existing technologies lack a real-time monitoring solution for users to assess this deformation.
Innovation Solution
Incorporating a swelling gauge on the battery pack case that measures deformation visually through temperature-sensitive pigments, geometric patterns, and scale portions, allowing users to assess the degree of swelling by observing changes in the gauge's shape or color.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a swelling gauge is added to the battery pack case, then the ability to measure deformation is improved, but the device complexity increases
Solution Approach 1:
The patent uses a visual copy of measurement markings (scale portions) printed or formed on the case surface to represent deformation. Instead of complex sensors, it creates a 2D visual pattern that replicates the deformation state, allowing users to measure swelling by observing changes in the pattern's geometry.
Solution Approach 2:
The patent incorporates temperature-sensitive pigments that change color or transparency based on temperature, providing visual feedback about thermal conditions that cause swelling. This allows the gauge to indicate both dimensional changes and temperature effects through optical property changes.
2Loss of information
If temperature-sensitive pigments are used in the swelling gauge, then the visibility of swelling conditions is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functions into a single gauge structure: deformation measurement through geometric patterns, temperature indication through color-changing pigments, and visual scaling through printed markings. This integration allows one component to provide comprehensive monitoring without requiring separate systems for each function.
3Area of stationary object
If multiple swelling gauges are placed on the case, then the coverage of measurement areas is improved, but the device complexity increases
Solution Approach 1:
The patent divides the case surface into multiple zones, each with its own swelling gauge pattern. This segmentation allows different regions of the battery pack to be monitored independently, capturing localized swelling that might occur at different positions due to thermal gradients or structural variations.
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 users to conveniently and instantly measure the degree of swelling, providing real-time feedback on the battery pack's condition and helping to prevent damage from excessive expansion.
Implementation Method 1
the swelling gauge is configured to measure an amount of deformation of the case by deforming with the case when the electrode assembly becomes deformed
Implementation Method 2
The swelling gauge may include temperature sensitive pigment. The swelling gauge may become transparent when the temperature of the case is greater than a particular temperature, and the swelling gauge may become visible when the temperature of the case is equal to or less than the particular temperature
Data Source
AI summary
A battery pack including a case, an electrode assembly having an electrode tab within the case, and at least one swelling gauge on the case, where the swelling gauge is configured to measure the amount of deformation of the case by deforming along with the case when the electrode assembly becomes deformed, and instantly and visually show the user the state or degree of swelling of the battery unit.