Electrochromic Battery Cell Indicators for Voltage Limit Screening
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Solution Overview
Problem
Existing systems lack efficient methods to monitor the health of high-voltage battery cells in electrified vehicles, particularly during assembly, storage, and end-of-life recycling, which can lead to inefficiencies and increased costs due to non-conforming cells entering the system.
Innovation Solution
A system utilizing electrochromic indicators, such as tungsten oxide, integrated into battery cells to change color based on voltage levels, combined with a visual monitoring system, allows for real-time detection of cells operating outside predefined voltage ranges, providing a permanent color change when voltage exceeds minimum or maximum limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional monitoring systems are used to monitor battery cell health, then measurement capability is provided, but device complexity and cost increase due to additional sensors and electronic components
Solution Approach 1:
The patent applies electrochromic materials that change color in response to voltage changes in battery cells. The electrochromic indicator transitions between different colors (e.g., clear to blue, or yellow to blue) based on the cell's voltage state, providing visual monitoring without complex electronics. This directly resolves the contradiction by replacing sensor-based measurement with optical color change detection.
Solution Approach 2:
The patent replaces electronic sensing and data processing systems with an optical visualization system. Instead of using sensors, microcontrollers, and display interfaces to monitor battery health, the system uses electrochromic materials that directly translate voltage states into visible color changes, eliminating the need for complex electronic monitoring infrastructure.
2Manufacturing precision
If electrochromic indicators are integrated into each battery cell, then manufacturing precision and cell identification capability improve, but device complexity increases due to integration requirements
Solution Approach 1:
The patent designs the electrochromic indicator to serve multiple functions: it acts as both a structural component of the battery cell and a monitoring device. The indicator is integrated into the cell assembly process, using the same manufacturing infrastructure for both battery production and indicator incorporation, thereby avoiding additional complexity while achieving precise voltage threshold detection.
Solution Approach 2:
The patent merges the battery cell structure with the monitoring function by integrating the electrochromic indicator directly into the cell assembly. Rather than adding separate monitoring components, the indicator becomes an inherent part of the cell structure, combining manufacturing processes and reducing overall system complexity while maintaining precise detection capabilities.
3Productivity
If visual monitoring systems are implemented to detect color changes, then productivity and non-conforming cell identification improve, but device complexity increases due to camera and controller requirements
Solution Approach 1:
The patent uses optical copying principles where cameras capture images of the electrochromic indicators. The visual system creates optical copies (images) of the color states, which can be analyzed to identify non-conforming cells. This approach maintains high productivity through rapid imaging while keeping the system relatively simple by using standard camera technology rather than complex analytical instruments.
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 efficient identification and removal of non-conforming battery cells, reducing assembly errors and enabling better recycling decisions by providing a visual, permanent indication of cell health status without the need for additional sensors.
Implementation Method 1
the electrochromic indicator comprises an electrochromic material with a metal strip connecting tab terminals associated with the one or more battery cells... the material changes in color or opacity in response to an electrical stimulus
Data Source
AI summary
A system includes system includes at least one cell stack including one or more battery cells and an electrochromic indicator associated with one or more battery cells. A visual system monitors each electrochromic indicator.