Battery voltage tester for end of cell

• US 5,494,496 A
• Filed: 05/05/1995
• Issued: 02/27/1996
• Est. Priority Date: 01/31/1991
• Status: Expired due to Fees

• Current Assignee: Eveready Battery Company Incorporated (Energizer Holdings, Inc.)
• Original Assignee: Eveready Battery Company Incorporated (Energizer Holdings, Inc.)
• Inventors: Bailey, John C., Huhndorff, Harry R.
• Primary Examiner(s): Skapars, Anthony
• Application Number:
  US08/435,625
• Time in Patent Office: 298 Days
• Field of Search: 29/623.1, 29/623.5, 324/435, 324/104, 429/90-93
• US Class Current: 29/623.5
• CPC Class Codes: G01D 7/005 Indication of measured value by colour change
• CPC Class Codes: G01R 31/364 Battery terminal connectors with integrated measuring arrangements
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 10/488 Cells or batteries combined with indicating means for external visualization of the condition, e.g. by change of colour or of light density
• CPC Class Codes: H01M 6/505 Cells combined with indicating means for external visualization of the condition, e.g. by change of colour or of light intensity
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

A battery is provided with an end-of-cell voltage indicating device which can be used to indicate the state-of-charge of the battery. The indicating device has a flexible substrate of the same peripheral configuration as the battery. The substrate has an indicating coating on one surface which is in thermal or electrical contact with a conductive circuit pattern which can be temporarily connected between the terminals of the battery on application of pressure to an indicated spot on the surface of the substrate. The conductive circuit means causes the indicating coating to undergo a visible change which is representative of the state-of-charge or voltage of the battery. A dual end-switched, integral battery and state-of-charge indicating device having two switches disposed on one end of the battery is also disclosed.

Claims

1. A method of producing an integral battery and state-of-charge indicating device, said method comprising:

providing a layer of transparent substrate material;

depositing a layer of thermochromic material on said substrate material;

depositing a conductive pattern having a first end and a second end on said thermochromic material;

depositing a layer of electrical insulation on said conductive pattern whereby said layer of electrical insulation covers substantially all of said conductive pattern except for said first end and said second end of said conductive pattern to form said state-of-charge indicating device;

providing a battery having a first battery end, a second battery end, and an outer surface extending between said first battery end and said second battery end, and a first terminal and a second terminal of opposite polarity;

affixing said state-of-charge indicating device on one of said first battery end and said second battery end such that (i) said layer of electrical insulation faces said end of said battery to which said device is affixed, (ii) said first end of said conductive pattern is either contacting said first terminal or spaced from and adapted to be placed in contact with said first terminal, and (iii) said second end of said conductive pattern is either contacting said second terminal or spaced from and adapted to be placed in contact with said second terminal.

2. The method of claim 1 further comprising:

providing a battery label having an end portion extending along at least a portion of the perimeter of said label;

applying said battery label to at least a portion of said battery outer surface such that said end portion of said label is disposed over the peripheral edge of said state-of-charge indicating device thereby securing and retaining said device affixed to said one of said first battery end and said second battery end.

3. The method of claim 2 wherein said battery label is formed from a heat shrink material, and said method further comprising:

heating said battery label to induce shrinkage of said heat shrink material on said battery.

4. The method of claim 1 wherein said state-of-charge indicating device has a circular, wafer-like form.

5. The method of claim 1 wherein said thermochromic material is a decolorizing thermochromic material, said method further comprising:

depositing a color layer on said layer of decolorizing thermochromic material prior to depositing said conductive pattern.

6. The method of claim 5 wherein said state-of-charge indicating device has a circular, wafer-like form.

7. The method of claim 1, said method further comprising:

depositing a second layer of thermochromic material on the first layer of said thermochromic material prior to depositing said conductive pattern, wherein said second layer of thermochromic material has a different activation temperature than said first layer of thermochromic material.

8. A method of producing an integral battery and state-of-charge indicating device, said method comprising:

providing a layer of transparent polymeric material;

depositing a region of electrochromic material having a first end and a second end on said layer of polymeric material;

depositing a first layer of electrical insulation over a portion of said electrochromic material between said first end and said second end of said electrochromic material;

depositing a conductive pattern having a resistive element disposed between a first end portion and a second end portion, on at least a portion of said electrical insulation such that (i) said first end of said electrochromic material is in electrical contact with said first end portion of said conductive pattern and (ii) said second end of said electrochromic material is in electrical contact with said second end portion of said conductive pattern;

depositing a second layer of electrical insulation over said conductive pattern thereby forming said state-of-charge indicating device;

providing a battery having a first battery end and a second battery end, and a first terminal and a second terminal of opposite polarity;

affixing said state-of-charge indicating device on one of said first battery end and said second battery end.

9. The method of claim 8 wherein said state-of-charge indicating device has a circular, wafer-like form.

10. The method of claim 8 further comprising:

providing a battery label having an end portion extending along at least a portion of the perimeter of said label;

applying said battery label to at least a portion of said battery outer surface such that said end portion of said label is disposed over the peripheral edge of said state-of-charge indicating device thereby securing and retaining said device disposed on said one of said first battery end and said second battery end.

11. The method of claim 10 wherein said battery label is formed from a heat shrink material, and said method further comprising:

heating said battery label to induce shrinkage of said heat shrink material on said battery.

12. A method of producing an integral battery and state-of-charge indicating device, said method comprising:

providing a layer of transparent substrate material;

depositing a first region of electrochromic material having a first end and a second end on said layer of substrate material;

depositing a second region of electrochromic material having a first end and a second end on said layer of substrate material, said second region distinct from said first region;

depositing over said first region of said electrochromic material and over said second region of said electrochromic material, a first layer of electrical insulation having a plurality of apertures, whereby a first aperture is disposed over said first end of said first region of said electrochromic material, a second aperture is disposed over said second end of said first region of said electrochromic material, a third aperture is disposed over said first end of said second region of said electrochromic material, and a fourth aperture is disposed over said second end of said second region of said electrochromic material;

depositing a first conductive pattern having a first portion and a second portion significantly longer than said first portion on said first layer of electrical insulation, whereby said first portion of said conductive pattern is disposed over said first aperture and in electrical contact with said first end of said first region of said electrochromic material through said first aperture, and said second portion of said conductive pattern is disposed over said third aperture and in electrical contact with said first end of said second region of said electrochromic material through said third aperture;

depositing a second layer of electrical insulation over said first conductive pattern;

depositing a second conductive pattern on at least one of said first layer of electrical insulation and said second layer of electrical insulation, said second conductive pattern having a first end portion and a second end portion, said first end and said second end separated by a resistor element, whereby said second end portion of said second conductive pattern is in electrical contact with said second end of said first region of said electrochromic material through said second aperture, and said second end portion of said second conductive pattern is also in electrical contact with said second end of said second region of said electrochromic material through said fourth aperture, and said first end portion of said second conductive pattern is in electrical contact with said first portion of said first conductive pattern;

depositing a third layer of electrical insulation over said second conductive pattern except for said first end portion and said second end portion of said second conductive pattern to form said state-of-charge indicating device;

providing a battery having a first battery end, a second battery end, an outer surface extending between said first end and said second end, and a first terminal and a second terminal of opposite polarity;

affixing said state-of-charge indicating device on one of said first battery end and said second battery end such that (i) said third layer of electrical insulation faces said end of said battery to which said device is affixed, (ii) said first end portion of said second conductive pattern is either contacting said first terminal or spaced from and adapted to be placed in contact with said first terminal, and (iii) said second end portion of said second conductive pattern is either contacting said second terminal or spaced from and adapted to be placed in contact with said second terminal.

13. The method of claim 12 wherein said state-of-charge indicating device has a circular, wafer-like form.

14. A method for producing an integral battery and state-of-charge indicating device, said method comprising:

providing a layer of a transparent polymeric material;

printing a first indicia indicating that said battery has a low state of charge, utilizing a first type of thermochromic ink on said layer of polymeric material;

printing a band over said first indicia utilizing a second type of thermochromic ink having an activation temperature different than said first type of thermochromic ink;

printing a second indicia indicating that said battery has a relatively high state of charge on said band;

depositing an electrically conductive pattern over said second indicia, said pattern having a first end and a second end;

depositing a layer of electrical insulation over said conductive pattern such that said electrical insulation does not cover said first end and said second end of said conductive pattern to form said state-of-charge indicating device;

providing a battery having a first battery end, a second battery end, and a first terminal and a second terminal of opposite polarity;

affixing said state-of-charge indicating device on one of said first battery end and said second battery end such that (i) said layer of electrical insulation faces said end of said battery to which said device is affixed, (ii) said first end of said conductive pattern is either contacting said first terminal or spaced from and adapted to be placed in contact with said first terminal, and (iii) said second end of said conductive pattern is either contacting said second terminal or spaced from and adapted to be placed in contact with said second terminal.