THERMOCHROMIC BATTERY TESTERS

Abstract: A status tester for an electrochemical cell (1), comprising an (1) elecrically resistive element (18), switchably contactible with the (18) terminals of the cell, and visual heat responsive means (24) thermally connected with the resistive means such that, on passage of electric current through the resistive element, heat generated thereby excites the heat responsive means, has at least two switches (65a, 65b) for one (65a, 65b) terminal, each switch being associated with an overall different electrical resistivity of the resistive element, thereby to allow testing for suitability for high and low drainage devices. Incorporation of a variable resistivity element, where resistance changes with ambient temperature, allows the tester to provide consistent results over a range of ambient temperatures.

Description: THERMOCHROMIC BATTERY TESTERS The present invention generally pertains to battery testers and, more particularly, relates to on-label thermochromic battery testers . Batteries are often stored before being used, such as by retailers before being sold. After purchase by a consumer, such batteries are again typically stored for some period of time prior to use. If the period of storage is significant, batteries may self-discharge. Therefore, it is desirable to utilise a battery tester to determine if a battery has retained sufficient charge to operate a desired device. It is also desirable, on frequent occasions, to determine the remaining life of batteries which are in use. Many "good" batteries are discarded simply because the user cannot recall how long they have been used in a particular device, i.e., a camera, tape deck, etc. For' similar reasons, batteries often reach a useless or near useless state of discharge when no replacements are readily available. Separate or stand-alone battery testers are known which indicate remaining battery power. However, such testers are easily misplaced and cumbersome to use. Battery testers have been described that are included in a label secured to a battery. One type of on-label battery tester is the thermochromic battery tester. These typically include a conductive element selectively connected between opposite terminals of the battery. A switch pad is located at one or both ends and is pressed by the user to connect the conductive element across the terminals of the battery. Heat is generated as a function of the resistivity of the conductive element and the current flowing from the battery. The level of current produced by the battery is one indicator of the remaining battery capacity. Thermochromic testers further include a thermochromic layer, which changes colour or visual appearance as a function of the heat generated by the conductive element. By changing the visual appearance of the thermochromic layer, a thermochromic on-label battery tester may provide an indication of the discharge level of the battery. For example, a thermochromic material that changes between opaque and transparent states may be utilised to expose indicia underlying the thermochromic layer, indicating that the battery is still "good" when a sufficient level of current is output from the battery. Batteries are used in a variety of applications having widely varying power consumption rates. For example, batteries used to power a camera flash are discharged at a much higher rate than batteries used to power radios, clocks, and flashlights. For such high-rate uses, a higher level of remaining battery capacity is required for the battery to continue to power the device. Thus, while a battery will have been considered to have been fully discharged for such high-rate uses, it may still be considered to be "good" for use in a clock or radio. Thus, a battery tester circuit that is calibrated for a single rate of discharge may not accurately reflect the relative discharge level for use in other applications. For example, if the on-label battery tester is calibrated for high-rate applications (i.e., constructed such that it indicates that the battery is no longer "good" when the battery capacity is MISSING UPON TIME OF PUBLICATION AUSENTE EN EL MOMENTO DE LA PUBLICACION MANQUANT AU MOMENT DE LA PUBLICATION reason, manufacturers of such thermochromic testers have printed 95 instructions on the battery label to only test the battery at a specified ambient temperature, such as room temperature. Because users will often ignore such instructions and because it may not be possible or convenient for the user to allow the battery to warm up or cool down to the specified temperature, inaccurate discharge 100 level readings are often obtained, causing the user to either discard a good battery or to wrongfully believe that a battery is still "good" when it is effectively discharged. Therefore, there exists a need for an on-label thermochromic 105 battery tester that will provide an accurate indication of whether the battery is good, regardless of the ambient temperature in which the tester is used. There is also a need for an on-label thermochromic battery 110 tester that provides an accurate indication of the discharge level of the battery, regardless of the discharge rate of the device in which the battery is to be used. It has now been surprisingly found that a reliable tester can 115 be provided by using a variable resistance element which changes resistance with ambient temperature, thereby assuring constancy of results obtained with a thermochromic tester. It has also been surprisingly found that it is easy to provide a multiply calibrated tester, for example, simply by extending the resistance element of 120 the tester and providing switches along its length. Accordingly, in a first aspect, the present invention provides a tester for an electrochemical cell, or battery, comprising an electrically resistive element, switchably contactible with the 125 terminals of the cell, and visual heat responsive means thermally connected with the resistive means such that, on passage of electric current through the resistive element, heat generated thereby excites the heat responsive means, characterised in that the resistive element is contactible with at least one terminal by means 130 of at least two switches, each switch being associated with an overall different resistivity of the resistive element. It will be appreciated that the electrically resistive element may be connectable to the terminals of the cell either directly, or 135 via one or more further connecting elements. Given that it is important in battery manufacture to keep costs as low as possible, then it is generally preferred that the resistive element should connect directly to the terminals. This is readily achieved by printing the resistive element onto a suitable substrate, such as a 140 label, or part thereof, and providing areas through which the label may be deformed to provide contact of the element with the battery. The resistive element may be as complex as desired although, for the reasons given above, it is preferred that the element be 145 kept as simple as possible, so that electrically conductive inks are generally suitable. Likewise, the switches may be made in any suitable manner, although it is generally preferred that the resistive element is 150 flexibly mounted on a substrate, such as the label, and is separated from its contact by a dielectric. A hole in the dielectric allows contact by exerting pressure on the label, which then resiles, or bounces back, when the pressure is released, thereby breaking contact. If desired, one part of the tester may be kept in 155 permanent contact with its respective terminal. It has been found that it is possible to provide a suitably modified and calibrated tester by merely providing two, or more, switches on a simple tester. Such testers comprise a resistive 160 strip of material, such as the inks referred to above, so that, the longer the strip, the more resistance there is. Where the switch at one end of the strip is located a relatively long way from the other switch at the other end, there is a greater resistance, and more battery power will be needed to heat the strip. Thus, in a simple 165 instance, there may be provided two switches at one end of the strip, the one more distal to the opposite end being for testing batteries used in high drain devices. Although not essential, it will be appreciated that it is desirable to indicate, somehow, on the relevant battery, which each switch is. 170 It may be preferable to provide several sets of switches, each relevant to a given temperature range, such as for arctic use, temperate use and tropical use, each being positioned accordingly for an expected temperature. 175 The visual heat responsive means may be any suitable material, or materials. In the simplest form, it is preferred that these take the form of thermochromic inks, which change colour and/or density with temperature. However, the present invention is not limited to 180 such, and it is entirely possible to couple a simple thermistor with an electrochromic ink, for example. It will be appreciated that such a set-up would generally run in parallel with the resistive element . 185 It has been found particularly advantageous to incorporate a variable resistance into a thermochromic battery tester. Thus, there is provided a tester for an electrochemical cell, or battery, comprising an electrically resistive element, switchably contactible with the terminals of the cell, and visual heat responsive means 190 thermally connected with the resistive means such that, on passage of electric current through the resistive element, heat generated thereby excites the heat responsive means, characterised in that at least part of the resistance element has a resistance dependent on ambient temperature. 195 It will be appreciated that the variable resistor may be in series or parallel with the remainder of the resistive element, where the resistive element is not entirely comprised of the variable resistance material. The skilled person will readily 200 appreciate the various possible constructions. However, it is generally preferred that the material increases resistance with temperature, so that the read-outs remain constant. Generally, the battery tester of the present invention 205 comprises a conductive heating element having one end including at least two switch pads for selective coupling of the conductive heating element to a second terminal of the battery. Each of the switch pads provides a different resistivity for the heating element when pressed, to thereby change the calibration of the tester for 210 different discharge rates. The battery tester further usefully includes discharge rate calibration indicia associated with each of the switch pads for indicating which switch pad to press for proper calibration at a relative rate of discharge. 215 Testers of the present invention can not only provide the user with the ability to select the proper calibration for the intended rate of discharge, but can also provide an accurate indication of the discharge level of the battery, regardless of the ambient temperature of the environment in which the battery tester is used. 220 This can be achieved by forming at least a portion of the conductive heating element from a variable resistivity material having a resistivity that changes in response to ambient temperature, thereby to compensate for varying ambient temperature. 225 Various preferred embodiments of the present invention are as follows. In a preferred embodiment, there is provided a battery tester comprising: a heating element for generating heat in response to current supplied from a battery, the heating element having first and second 230 end segments and a central segment disposed between the end segments, the first end segment being adapted to be coupled to a first terminal of the battery and the second end segment includes at least two switch pads for selective coupling of the second end segment to a second terminal of the battery, each of the switch pads 235 providing a different resistivity for the heating element when pressed, to change the calibration of the tester for different discharge rates; an indicator provided in proximity to the heating element, the indicator having a visual property that changes in response to the 240 heat generated by the heating element; and discharge rate calibration indicia associated with each of the switch pads for indicating which switch pad to press for proper calibration at a relative rate of discharge. 245 It will be appreciated that the battery tester of the present invention is preferably configured such that the heating element, the indicator, and the indicia can be included in a battery label. It is generally preferred that the battery tester of the 250 present invention has at least a portion of the heating element made of a variable resistivity material having a resistivity that changes in response to ambient temperature. The variable resistivity material preferably has a resistivity that increases as ambient temperature increases, ideally such that the tester gives a similar 255 or very close result over a range of temperatures in which the battery is used. It is generally advantageous for all of the heating element to be made of the variable resistivity material, although it will be 260 understood that there are many ways that the skilled person can configure a tester of the present invention that do not entail the entire element to be made of the variable resistivity material, such as are described herein. For example, in one preferred embodiment, the heating element includes a first portion made of a variable 265 resistivity material and a second portion made of a non-variable resistivity material. The indicator may be any material which responds visibly or can be coupled to provide a visual response. However, preferably, 270 the indicator is made of a thermochromic material, i.e. one that changes colour in response to heat generated by the heating element. It will be appreciated that the present invention provides a battery label comprising a tester of the invention. A preferred 275 battery label comprises: a label substrate; a conductive element provided on the label substrate and adapted to be coupled to opposite terminals of a battery, the conductive element changing temperature in response to changes in 280 discharge level of the battery and including a material having a resistivity that changes in response to ambient temperature; and an indicator provided on the conductive element and having a visual property that changes in response to changes in temperature of the conductive element, 285 wherein the conductive element includes first and second switch pads provided at one end of the conductive element, the first switch pad, when pressed, coupling the conductive element to one of the two battery terminals and establishing a first resistance for the conductive element, the second switch pad coupling the 290 conductive element to the same battery terminal and establishing a second resistance for the conductive element when pressed, the first resistance being a resistance required for proper calibration at a first discharge rate, and the second resistance being a resistance required for proper calibration at a second discharge rate and being 295 higher than the first resistance. Labels and testers of the present invention preferably have a protective layer overlying the label substrate, the conductive element, and the indicator. 300 There is also provided a method of calibrating an on-label battery tester for different battery discharge rates, the battery tester including a conductive element adapted to be coupled between opposite terminals of a battery and an indicator element proximal to 305 the conductive element such that the indicator element changes its visual appearance in response to changes in temperature of the conductive element, the method comprising the steps of: providing a plurality of switch contacts at one end of the conductive element for selectively altering the resistance of the 310 conductive element, the selectable resistances of the conductive element including at least a first resistance at which the battery tester is calibrated for a relatively high discharge rate and a second resistance at which the battery tester is calibrated for a relatively low discharge rate; and 315 selecting and pressing one of the plurality of switch contacts associated with a particular battery discharge rate. ' It will be appreciated that the method is applicable to testing a battery having such a label. 320 The present invention also extends to batteries having testers of the invention located thereon. In a preferred embodiment, there is provided a battery comprising: an electrochemical cell having a positive terminal and a negative terminal; 325 a label substrate adhered to an outer peripheral surface of the electrochemical cell; a conductive element provided on the label substrate and coupled to the terminals of the electrochemical cell, the conductive element changing temperature in response to changes in discharge 330 level of the electrochemical cell; and an indicator provided in the proximity of the conductive element, the indicator having a visual property that changes in response to the heat generated by the conductive element, wherein the conductive element includes first and second switch pads 335 provided at one end of the conductive element, the first switch pad, when pressed, coupling the conductive element to one of the two battery terminals and establishing a first resistance for the conductive element, the second switch pad coupling the conductive element to the same battery terminal and establishing a second 340 resistance for the conductive element when pressed, the first resistance being a resistance required for proper calibration at a first discharge rate, and the second resistance being a resistance required for proper calibration at a second discharge rate and being higher than the first resistance. 345 The present invention will now be further illustrated with reference to the accompanying drawings, in which: Figure 1 is an illustration of a battery having a battery tester label in accordance with this invention disposed about the 350 outer periphery of the battery; Figure 2 is a cross section of the battery tester label taken along plane II-II of Figure 1; Figure 3 is an exploded view of a sub-component of the battery tester label, referred to herein as the tester device; 355 Figure 4 is a top plan view of the inserted tester device; Figure 5 is a bottom plan view of the inserted tester device, the cross-hatching indicating a layer of adhesive; Figure 6 is an exploded view of another sub-component of the battery tester label, referred to herein as the base layer; 360 Figure 7 is a cross section of a battery and the battery tester label; Figure 8 is an exploded view of the battery tester label; Figure 9 is a top view of a conductive circuit constructed in accordance with a first variation of a second embodiment of the 365 present invention; Figure 10 is a cross section of a conductive circuit shown in Figure 9 taken along plane X-X; Figure 11 is a top view of a conductive circuit constructed in accordance with a second variation of the second embodiment of the 370 present invention; Figure 12 is a cross section of the conductive circuit shown in Figure 11 taken along plane XII-XII; Figure 13 is a top view of a conductive circuit constructed in accordance with a third variation of a second embodiment of the 375 present invention; Figure 14 is a cross section of a conductive circuit shown in Figure 13 taken along plane XIV-XIV; Figure 15 is a top view of a conductive circuit constructed in accordance with a fourth variation of the second embodiment of the 380 present invention; and Figure 16 is a cross section of the conductive circuit shown in Figure 15 taken along plane XVI-XVI. Referring to Figure 1, this illustrates a battery and label 385 assembly 1 comprising a battery can 2, a negative terminal 4, and a positive terminal 6. Can 2 may be in electrical contact with positive terminal 6. Battery 1 may include one or more electrochemical cells, which may be primary cells or secondary cells. Extending around and attached to the periphery of can 2 is a 390 label 10 including a battery tester device 15, which is the subject of this invention. As shown, tester device 15 comprises switches 64, 65a, and 65b which activate tester 15 to indicate the state of charge of the battery by exposing indicia 23 or producing some other visual indication. 395 As illustrated in Figures 2-5, tester device 15 generally comprises a laminate or layered assembly having a substrate layer 20, an elongated electrically conductive circuit 18 disposed on a first face of substrate 20, and a pressure-sensitive adhesive 16 400 disposed on portions of both conductive circuit 18 and the first face of substrate 20. Adhesive 16, indicated by cross-hatching in Figure 5, is preferably applied over conductive layer 18 in the pattern illustrated. Adhesive 16 is omitted from those areas which will overlie printed insulation 44 and switch pads 42, 42a, and 42b 405 (Figures 6 and 8) when the tester 15 is affixed to a base laminate 30. This adhesive pattern retards moisture from migrating to switch segments 60, 61a, and 61b of conductive circuit 18, while not interfering with the function of either the switches or the insulation discussed below. 410 Tester device 15 further comprises one or more graphic layers 22, preferably of decorative ink, and indicia 23 that are disposed on a second face of substrate 20 opposite the face containing conductive circuit 18. Tester device 15 also comprises a layer of a 415 temperature sensitive (i.e., thermochromic) indicating material 24 that is deposited upon the second face of substrate 20, preferably upon graphic layers 22 and indicia 23. A layer of a clear protective coating (not shown) is preferably deposited over indicator layer 24 and optionally upon graphic layers 22 and other 420 exposed regions of the second face of substrate 20. By providing a plurality of switches 65a and 65b on one side of a central display area 62 of conductive circuit 18, the resistance of conductive circuit 18, as presented between the two 425 contacted terminals of the battery, may be selectively varied. With a switch configuration as shown in the drawings, pressing switch 65a would present a lower resistance than if switch 65b were pressed. Battery tester device 15 also preferably includes indicia 90a 430 and 90b printed on the outermost layer of device 15 in association with each of switches 65a and 65b in order to indicate which switch should be pressed for high- or low-rate applications. Because the high-rate discharge application requires greater battery capacity to be considered "good," the resistance of conductive circuit 18 must 435 be greater than that for lower discharge rate applications for proper calibration. Thus, in the examples shown, switch 65a would be used for low-rate devices such as a radio, and switch 65b would be used for high-rate devices such as a photo-flash. 440 As will be explained in more detail below, the second switch may be provided by adding a little additional conductive ink and punching one more hole through the battery label to allow for contact. Thus, the additional feature of providing for two separate calibrations for different discharge rates may be accomplished at 445 very low cost. In one embodiment of the present invention, conductive circuit 18, which serves as a heating element, is printed in the pattern illustrated in Figures 3, 5, and 8, using a material having a 450 resistivity that varies as a function of temperature. Such conductive materials preferably have a positive temperature coefficient (PTC) of resistance causing the resistance of conductive circuit 18 to increase with the ambient temperature of the environment in which the tester may be used. Thermistor-type solid 455 state materials may also be used. Given the dimensions typically used for the type of conductive circuit 18 shown in the drawings then, for a temperature range of 10 D C to 40 D C (50 D F to 104 D F) , the resistivity of conductive circuit 460 18 will preferably change by a factor of 25. Although silver conductive inks conventionally used for printing such conductive circuits do not exhibit such characteristics, carbon-based compositions exist that may be employed for this purpose. Examples of such carbon-based compositions include ethylene-ethylacrylate 465 copolymer; polyolefins and polyolefin-paraffin mixtures, e . g. , polyethylene; polyethylene oxide; and nylon 66. An advantage in forming conductive circuit 18 entirely of a single variable resistance material is that conductive circuit 18 may be produced using a single print station. 470 In a second embodiment of the present invention, a portion of conductive circuit 18 is formed using a material having a non- variable resistivity and a portion is made from a material having a variable resistivity. The portion of conductive circuit 18 that is 475 made of a variable resistivity material may be electrically coupled in series with the other portion of conductive circuit 18 or be in parallel, as described below. Preferably, the material used to form the portion of non-variable resistivity is a silver ink and the material used to form the variable resistivity portion is one of the 480 above carbon-based compositions. Figures 9-12 show a conductive circuit of the second embodiment of the present invention with the portion of variable resistance coupled in series with the portion of non-variable 485 resistance. As shown in Figures 9 and 10, such a conductive circuit 18 may be formed by printing the non-variable resistivity portion in essentially the same pattern as discussed above, with respect to the first embodiment, except that a conductive ink is used that has a constant resistivity, and a gap 82 is provided in the deposited 490 layer to electrically isolate switch segments 60, 61a, and 61b. Subsequently, a layer 80, formed of a material having a variable resistivity, is printed across gap 82 in contact with edges 84 and 86 of the first printed material that are adjacent gap 82. 495 An alternative method and construction for a series-coupled conductive circuit 18 of the second embodiment is illustrated in Figures 11 and 12. In this alternative construction, contact portions 84 and 86 of the non-variable resistivity material overlap a layer 80 of. variable resistivity material sandwiched therebetween. 500 By providing a layer 80 of variable resistivity material in series with the remaining portion of conductive circuit 18, the total resistance appearing between switch segments 60, 61a, " and 61b will be equal to the sum of the resistance of the segments 60, 61a, and 61b and layer 80. Thus, as ambient temperature increases, so will 505 the resistance of layer 80 and the total resistance of conductive circuit 18. This increase in resistance decreases the current flowing through central portion 62 of conductive circuit 18 thereby resulting in less heat being generated by central portion 62 which underlies thermochromic layer ' 24. 510 Figures 13-16 illustrate the parallel connection approach to the second embodiment of the present invention. To connect the layer 80 of variable resistivity material in parallel with the portion of non-variable resistivity, the latter portion may be 515 printed having first and second legs 88 and 89 extending perpendicularly from an axis between switch segments 60, 61a, and 61b, while being provided with a gap 82 therebetween. Subsequently, a layer 80 of variable resistivity material may be printed across gap 82 in series with legs 88 and 89 and in parallel with at least a 520 portion of the non-variable resistivity material of conductive circuit 18. An alternative construction is shown in Figures 15 and 16 in which legs 88 and 89 overlap one another with layer 80 of variable resistivity material provided therebetween. Like the series-connected variation of the first embodiment, the parallel 525 connected variation effectively increases the resistance of conductive circuit 18 in response to an increase in ambient temperature. The tester device 15, as shown in Figures 2-5 and 8, is 530 preferably prepared as follows. A plastic film is provided as substrate 20. Although Figure 3 illustrates substrate 20 as being transparent, substrate 20 could be formed from a wide variety of other materials including opaque and translucent materials. Conductive circuit 18 is deposited on one face of substrate 20. 535 Conductive circuit 18, having the properties discussed above, is preferably deposited in the form of a pattern comprising two distal regions and a medially disposed area 62 which undergoes an increase in temperature upon passage of electrical current. The pressure- sensitive adhesive material 16 is deposited on at least portions of 540 either or both conductive circuit 18 and a face of substrate 20. As previously noted, particular regions of conductive circuit 18 are left exposed and not covered with pressure-sensitive adhesive 16; namely, the switch segments 60, 61a, and 61b and area of controlled resistivity 62. A silicone-coated release liner, such as a 545 silicone-coated paper or plastic film (not shown) , is applied onto the previously deposited pressure-sensitive adhesive 16 to facilitate handling and/or storage of tester device 15. Graphics and/or other labelling colours 22 in the form of a 550 layer or layers of decorative ink and indicia 23 are printed onto the opposite side of substrate 20 from that on which the conductive circuit 18 is positioned. It is preferred that indicia 23 be disposed directly above the area of controlled resistivity 62 of conductive circuit 18 located on the other side of substrate 20. 555 Additional graphics are also preferably printed to designate switch regions 64, 65a, and 65b. If necessary, one or more curing operations may be performed to cure, or partially cure, the graphic or colouring layers. 560 On the same side of the substrate as the graphics and/or labelling colours, a thermochromic ink or other indicator material 24 is deposited onto substrate 20 such that it is situated directly above the area of controlled resistivity 62 of conductive circuit 18, preferably over indicia 23. A clear protective coating, such as 565 a varnish film, is then applied over and onto the indicator material, and optionally over the remaining regions of this side of substrate 20 to protect such regions from damage by subsequent manufacturing or storage operations. Each of the previously- described layers or elements preferably have a thickness of from 570 about 0.00005 inch [0.0013 mm] to about 0.005 inch [0.13 mm]. The tester device, if necessary, can be cut to an appropriate size. The second sub-component of the preferred embodiment label 10 is a base laminate 30. As illustrated in Figures 2 and 6, base 575 laminate 30 is a laminate, or layered structure, comprising a substrate 34, with one face having a layer of pressure-sensitive adhesive 32 for subsequent contact with a battery, and another face having one or more layers as follows: a metallisation layer 36; a primer and/or decorative layer 38; an electrical insulation layer 580 40; and a thermal insulation layer 44. Also residing proximal to the thermal insulation layer are one or more switch throw pads 42 described in greater detail below. Base laminate 30 is preferably prepared as follows. A plastic 585 film is provided for the base layer substrate 34. The pressure- sensitive adhesive material 32 is deposited upon the face of the base layer substrate 34 that will subsequently face and contact the battery can 2. A silicone release liner is applied on the pressure- sensitive adhesive to facilitate handling and other processing 590 operations. On the opposite face of base layer substrate 34, one or more graphic or labelling colour layers are deposited, for instance, by printing. Preferably, metallisation layer 36 is utilised to provide a decorative reflective layer. If a metallisation layer is deposited, it will, in most instances, be necessary to deposit a 595 receptive coating or primer layer 38 onto those regions of metallisation layer 36 upon which other decorative layers are to be deposited. Primer layer 38 may in itself be a decorative layer. It is also desirable to deposit a layer of electrical insulation 40 upon metallisation layer 36 and/or primer layer 38 to prevent 600 electrical contact, i.e., shorting, between layer 36 and the conductive circuit 18 ' of tester device 15 during assembly of label 10. Thermal insulation 44 is positioned in an area of base layer 605 substrate 34 that will be disposed beneath both the indicator material 24 and the maximum resistance area 62 of conductive circuit 18 of the tester device 15. This thermal insulation reduces heat transfer from the area of controlled resistivity 62 of conductive circuit 18 to the battery. If such heat transfer is not controlled 610 and the battery is permitted to act as a heat sink, the change in temperature at indicator material 24 may be insufficient to provide an accurate indication of the battery state of charge. Thermal insulation 44, as shown, preferably comprises a 615 plurality of apertures 46c which, when assembled into the laminate structure of the preferred label 10, provide air pockets which further thermally insulate the conductive circuit 18 from the battery. Optionally, a larger region of air space or void may be formed to serve as insulation by depositing a suitable spacer 620 material onto the base laminate 30. The preferred insulative pattern is a series of islands printed onto laminate 30 in the manner shown in Figure 1A of US-A-5, 389, 458. Switch throw pads 42a and 42b are also formed, surrounding 625 switch apertures 46a and 46b, respectively. These raised pads provide spacing between switch segments 61a and 61b of the conductive circuit 18 and battery can 2, and significantly minimise the occurrence of accidental switch closure. Raised switch throw pads 42a and 42b are preferably formed by depositing or printing a 630 dielectric ink or other suitable material. A second switch pad 42 may be formed proximate a switch aperture 47 as shown in Figures 6 and 8. This pad has not been found necessary for proper functioning of the tester. 635 In all of the foregoing operations, one or more cure steps may be utilised when depositing or printing any of the previously- described layers, particularly the decorative inks. Each of the previously-described layers or elements preferably has a thickness from about 0.00005 inch [0.0013 mm] to about 0.005 inch [0.13 mm]. 640 Switch apertures 46a, 46b, and 47 are preferably formed in base laminate 30, after printing thermal insulation 44 and switch throw pads 42, 42a, and 42b. Such apertures are preferably formed by suitable punching operations. Registry problems can be minimised 645 by printing what is to become switch pads 42a and 42b as solid disks and thereafter punching apertures 46a and 46b centrally through these disks. Switch apertures are formed in the base laminate 30 so that, when the previously-described inserted tester device 15 is combined with base laminate 30, switch apertures 46a, 46b, and 47 650 are located directly beneath the distal switch segments 60 and 61 of conductive circuit 18. The preferred geometry for such switch apertures is a notch 47 for the negative switch segment 64 and a circle 46a/46b for the positive switch segments 65a and b. 655 The switches utilised in the battery tester label are preferably membrane switches such that a switch segment 60, 61a, or 61b of conductive circuit 18 overlies apertures 46a, 46b, and 47 in base laminate 30. Apertures 46a, 46b, and 47 in base laminate 30 enable contact between conductive circuit 18 and either a battery 660 terminal or can 2 on the other side of base laminate 30. Upon application of force to a switch segment, such as by applying finger or thumb pressure at switch segments 64, 65a, or 65b, a portion of the switch segment is pressed or deformed through the opening in base laminate 30 to contact the battery terminal or can 2. Upon 665 release of the pressure, the portion of the switch segment resiles from the battery terminal or can 2, thus bringing it out of electrical contact with the battery. This configuration is referred to herein as "switchably connected." 670 A significant advantage provided by the present invention battery tester label is the absence of electrically conductive layers or members to electrically connect and disconnect the tester, i.e., conductive circuit 18, to and from the battery. This is remarkable and of significant benefit particularly when 675 manufacturing a battery tester label in large volumes and at a high rate. This advantage of eliminating otherwise necessary electrically conductive switching components is achieved in part by providing a first switch 64 which is disposed very near a battery terminal, such as negative terminal 4. Such close proximity 680 eliminates the need for additional conductive elements to electrically connect an end of circuit 18 to the negative battery terminal. It is most preferred to fold or shrink the peripheral edge of label 10 over the battery end at which the negative terminal is disposed, as illustrated in Figure 1. 685 The tester device 15 can be combined with base laminate 30 as follows and is best shown in Figure 8. The tester device is positioned onto or adjacent base laminate 30 so that " switch segments 60, 61a, and 61b of conductive circuit 18 overlie switch apertures 690 46a, 46b, and 47, respectively. Tester device 15 is oriented such that the layer of pressure-sensitive adhesive 16 (the release liner having been removed if previously applied) is facing base laminate 30. Upon application of sufficient pressure to tester device 15 and base laminate 30, the two assemblies are securely attached to each 695 other via adhesive 16, and form the preferred battery tester label 10 of the present invention. Optionally, a clear laminating adhesive 52 is deposited upon the outward facing surface of the resulting tester label as illustrated in Figure 2, and a clear film 54, such as polyvinyl chloride or polyester, is applied over the 700 coating and the resulting assembly cured. A coating of adhesive 52 and film 54, when applied onto the tester label, provide protection for the tester device and components thereof. It is most preferred that the transparent protective layer resulting from adhesive coating 52 and film 54 is deposited upon the battery tester label 705 prior to application of the tester label to a battery. The resulting battery tester label 10 is appropriately die cut to the size of the battery desired. Upon removal of excess trimmed label, a plurality of individual tester labels are left remaining on 710 the release liner previously applied to substrate 34 of base laminate 30. The liner and label array may then be cut into strips and wound into a roll and stored for subsequent application to batteries . 715 The substrate layer, utilised for either or both the base layer substrate 34 and the tester device substrate 20, can be made of any appropriate dielectric polymer material. It is preferable to use a dielectric polymer material that will shrink when assembled on a battery. Generally, polyvinyl resins, polyolefin resins, 720 polyester resins and the like are suitable. Specific examples include polyvinyl chloride, polyethylene and polypropylene. It is contemplated that substrate 20 could also be formed from other dielectric materials besides plastics such as paper or other cellulose-based materials. The thickness of the substrate layers is 725 not particularly limited, but is preferably in the range of from about 0.0005 to about 0.005 inch [0.0013 - 0.13 mm], and most preferably from about 0.001 to about 0.003 inch [0.025 - 0.076 mm]. The previously-described indicator layer 24 in the inserted 730 tester device 15 comprises a thermally sensitive material for indicating the capacity of the battery. The preferred thermally sensitive materials change colour in response to a temperature change, which change is readily viewable by a consumer. Thus, the consumer, based on the colour change, can determine whether the 735 battery is good or needs to be replaced. Examples of such thermally sensitive materials include liquid crystal materials and thermochromic inks. Examples of suitable liquid crystal materials are of the cholesteric type, such as cholesteryl oleate, cholesteryl chloride, cholesteryl caprylate and the like. The indicator 740 material could change from coloured to colourless, colourless to coloured, or from one colour to a second colour. A tricolour material could also be used. The preferred battery tester 10 shown in Figures 1-8 utilises an indicating material which changes from coloured to colourless upon activation to reveal indicia 23 745 underneath the indicator material 24. Indicating materials, such as thermochromic inks, can be used singly or in combination. For example, in one embodiment, different layers of the indicating material are employed. The layers are 750 activated at different temperatures or states and can be designed to change different colours at different temperatures. For example, the layer of indicating material activated at the highest temperature will preferably be the bottom layer, i.e., closest to the battery, and the outer layers are arranged in decreasing 755 temperatures of activation with lowest temperature material in the outermost layer, and so, readily viewable at the exterior of the battery. Any one or all of switch segments 60, 61a, and 61b of 760 conductive circuit 18 can be out of contact with the respective terminals of the battery so that the tester circuit is open. In one embodiment of the invention, one of the switch segment ends is permanently in electrical connection with one terminal of the battery, while the other switch segment ends are positioned out of 765 contact with the other battery terminal. By forcing one of the switch segment ends into contact with the other battery terminal, the switch is closed and the tester circuit is completed to test the battery with respect to the discharge rate selected. The most preferred embodiment is to utilise a dual switch tester as shown in 770 the accompanying drawings. The labels useful in this invention can also comprise additional electrical and thermal insulative layers, printing layers, protective layers and the like. Suitable materials for use 775 as the different layers are those typically used in battery labels and include plasticised or unplasticised polyvinyl chloride (UPVC) , polyesters, metallic films, paper and the like. The tester label can be in the form of a shrinkable tube label in which a battery is encased. 780 The battery tester label of the present invention is preferably applied to a battery as follows. A previously assembled tester device 15, having its underside containing pressure-sensitive adhesive 16 exposed, is aligned with a previously formed base 785 laminate 30 (disposed upon a releasable liner) such that the electrically conductive circuit 18 of the inserted tester device is positioned to contact the thermal insulation 44 of base laminate 30. Upon application of sufficient pressure, the respective layers are secured and joined to one another via pressure-sensitive adhesive 16 790 disposed on the mating surface of tester device 15. The resulting battery tester label 10 is then attached to the outer periphery of a battery can 2 by removing the liner of base laminate 30 to expose adhesive 32 on the underside of label 10 and contacting the underside of base laminate 30 to the battery can 2. Figure 7 (not 795 to scale) illustrates a typical cross section of the battery and label assembly 1. It is also possible to produce the tester label of the present invention and apply such to a battery without using pre-assembled tester device and/or base laminate sub-components. In another embodiment, the battery and tester label assembly is formed 800 by combining the tester device 15 and base laminate 30 as previously described. The resulting label is then itself stored, such as on a releasable liner in a wound roll, until needed. The present invention also enables the production of multiple 805 tester label assemblies. That is, a plurality of tester devices 15 can be aligned and mated with a plurality of base layer components, i.e., regions of thermal insulation, switch throw pads, and switch apertures, disposed upon and defined within a common base layer to form a plurality of battery tester labels 10. The resulting set of 810 multiple label assemblies can then be stored for subsequent use, or separated into smaller groups of multiple label assemblies or into individual battery tester labels. It will be appreciated by those skilled in the art, that a 815 plurality of switches 65a and 65b may be provided to allow for dual calibration without utilising any materials in the conductive circuit 18 that have a variable resistivity. Those skilled in the art will also recognise that more than two switches 65a and 65b may be provided to allow for calibration at various intermediate rates 820 of discharge. Although the tester circuit of the present invention has been described as being implemented in a battery label, it will be appreciated by those skilled in the art that the tester circuit may 825 be provided on the battery packaging, on a separate tester strip, on the housing of a battery pack, or on a device that utilises batteries .

Claims: CLAIMS : 830 1. A status tester for an electrochemical cell, comprising an electrically resistive element, switchably contactible with the terminals of the cell, and visual heat responsive means thermally connected with the resistive means such that, on passage of electric current through the resistive element, heat generated thereby 835 excites the heat responsive means, characterised in that the resistive element is contactible with at least one terminal by means of at least two switches, each switch being associated with an overall different electrical resistivity of the resistive element. 840 2. A tester according to claim 1, wherein discharge rate calibration indicia are associated with each switch to indicating which switch to use for proper calibration at a relative rate of discharge of the battery. 845 3. A tester according to claim 1 or 2, wherein at least a portion of the heating element is made of a variable resistivity material whose resistance is dependent on ambient temperature. 4. A tester according to claim 3, wherein the variable 850 resistivity material has a resistivity that increases with increase in ambient temperature. 5. A tester according to claim 3 or 4, wherein substantially all of the resistive element is made of the variable resistivity 855 material. 6. A tester according to any preceding claim, wherein the resistive element has a first portion of variable resistivity material and a second portion of non-variable resistivity material. 860 7. A tester according to any preceding claim, wherein the visual means comprises a thermochromic material that changes " colour in response to heat generated by the resistive element. 865 8. A tester according to any preceding claim, adapted for incorporation into a battery label. 9. A battery label comprising a tester according to any preceding claim. 870 10. A label according to claim 9, further having a protective layer overlying the resistive element and the visual means. 11. A battery having a label or tester according to any preceding 875 claim.

Inventors: BAILEY JOHN C, BAILEY, JOHN, C.
Applicants: EVEREADY BATTERY INC, EVEREADY BATTERY COMPANY, INC.
Application year: 1998
Main classification: G01R31
IPC codes: G01D7, G01R31, H01M2, H01M6, H01M10