Battery Acoustic Inspection for Hidden Defect Detection
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Solution Overview
Problem
Current methods for detecting defects in batteries, such as x-ray or CT inspection, are invasive and ineffective for identifying deep-seated manufacturing or operational defects, leading to costly failures and inefficiencies in battery production.
Innovation Solution
A suite of non-destructive, acoustic inspection systems and methods using rastering systems with interchangeable transducer configurations and dynamic inspection parameters to accommodate various battery shapes and sizes, performing one-sided and double-sided acoustic measurements to detect defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If x-ray or CT inspection methods are used to detect defects in batteries, then measurement capability is improved, but the method becomes invasive and ineffective for identifying deep-seated defects
Solution Approach 1:
The patent replaces x-ray/CT inspection methods with acoustic emission detection. Instead of using penetrating radiation (x-ray/CT), the system uses acoustic sensors to detect sound waves generated by defect propagation within the battery. This substitution eliminates the harmful invasive nature of x-ray while maintaining or improving defect detection capability, particularly for deep-seated defects that generate acoustic signals during operation.
Solution Approach 2:
The patent introduces acoustic emission signals as an intermediary to detect defects. Rather than directly imaging the battery structure with x-ray, the system detects the acoustic waves emitted by defects as they propagate or evolve. This intermediary approach allows indirect observation of deep-seated defects through their acoustic signatures, making the detection non-invasive while highly effective.
2Productivity
If traditional inspection methods are used, then manufacturing process time is reduced, but production costs increase due to damaged cells and quality issues
Solution Approach 1:
The patent implements acoustic emission monitoring during the manufacturing process to detect defects in real-time before they propagate or cause cell damage. By performing preliminary detection of manufacturing defects (such as separator tears, electrode delamination, or welding issues) during assembly, the system prevents defective cells from advancing to later production stages, thereby maintaining high reliability without slowing down production.
Solution Approach 2:
The system provides real-time feedback on battery cell quality during manufacturing by continuously monitoring acoustic emission signals. This feedback mechanism allows immediate identification of defects, enabling operators to adjust processes or remove defective cells promptly, thus preventing quality issues from escalating and reducing waste without compromising production throughput.
3Adaptability or versatility
If acoustic inspection parameters are made dynamic and interchangeable, then adaptability to different battery shapes and sizes is improved, but device complexity increases
Solution Approach 1:
The patent implements dynamic and interchangeable acoustic inspection parameters that can be adjusted based on the specific battery geometry being inspected. The system allows modification of transducer placement, acoustic wave frequency, and scanning patterns to match different battery shapes and sizes. This dynamic adaptability enables a single inspection system to handle multiple battery formats without requiring completely different equipment for each cell type.
Solution Approach 2:
The patent creates a universal acoustic inspection platform that can inspect various battery types (cylindrical, prismatic, pouch) using the same core system. By making the inspection parameters interchangeable and the transducer configurations adaptable, the system achieves multi-functionality, allowing one device to serve multiple inspection purposes across different battery form factors, thereby reducing the need for multiple specialized inspection systems.
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 accurate and reproducible detection of defects in batteries, reducing production costs and improving quality by identifying hidden defects without damaging the cells, thus enhancing manufacturing efficiency and reliability.
Implementation Method 1
at least one transducer configured to transmit acoustic signals through the battery cell
Implementation Method 2
at least one transducer configured to receive acoustic signals
Data Source
AI summary
Aspects of the present disclosure are directed to a suite of testing apparatuses and non-destructive, acoustic inspection methods for scanning and inspecting batteries to determine and characterize various physical phenomena in these batteries. In one aspect, a rastering system for non-invasive and acoustic inspection of battery cells includes a holder for placing a battery cell inside the system for the acoustic inspection, at least one transducer configured to perform acoustic measurements on the battery cell, and a controller configured with inspection parameters for performing the acoustic measurements, the inspection parameters being dynamic and interchangeable depending on at least one or more of a shape, a size, and a form factor of the battery cell.