Battery Bonding Flow Sensing for Electrode Assembly Defect Detection

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Solution Overview

Problem

The existing methods for determining the bonding quality of secondary batteries are operator-dependent and lack accuracy, leading to inconsistent criteria for determining bonding defects.

Innovation Solution

A battery bonding device equipped with a flow sensor that measures the adhesive flow rate using ultrasonic waves and a control system to determine whether the electrode assembly is defective, with an output for displaying or alerting any defects, ensuring precise adhesive application and bonding quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If visual inspection by operator is used to determine bonding quality, then the method is simple and easy to implement, but the measurement precision and reliability are poor due to operator dependency and varying criteria

Engineering Contradiction:

Improveease of implementationVSAvoidbonding quality detection accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent replaces the manual visual inspection method with an automated flow sensor-based detection system. The flow sensor objectively measures adhesive flow rate through electrical signals, eliminating operator dependency and subjective judgment variations while maintaining ease of implementation through automated integration into the bonding device.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a feedback mechanism where the flow sensor continuously monitors adhesive flow rate and provides real-time data to the control unit. The control unit compares measured flow rates against reference values and provides feedback to determine bonding quality, enabling automated quality control with consistent criteria.

Inventive Principle:

Principle #23Feedback

2Device complexity

If visual inspection by operator is used to determine bonding quality, then the device complexity is low, but the reliability of bonding quality determination is poor

Engineering Contradiction:

Improvedetection system complexityVSAvoidbonding defect determination reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent substitutes the simple but unreliable visual inspection system with a flow sensor-based measurement system that provides objective, repeatable measurements. The increased device complexity is justified by the significant improvement in reliability, as the flow sensor provides consistent, quantifiable data independent of operator variability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The bonding device performs self-diagnosis of bonding quality through automated flow rate measurement and evaluation. The control unit automatically determines whether bonding is normal or defective based on pre-set reference values, eliminating the need for manual inspection and improving reliability through consistent automated judgment.

Inventive Principle:

Principle #25Self-service

3Productivity

If manual visual inspection is used, then the manufacturing process is simple, but the productivity is reduced due to inconsistent quality determination requiring rework

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidbonding detection system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements automated feedback control where the flow sensor continuously monitors adhesive flow rate and the control unit immediately determines bonding quality. This real-time feedback mechanism enables rapid quality assessment, prevents defective products from proceeding to subsequent processes, and improves productivity by eliminating rework associated with inconsistent manual inspection.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual visual inspection with an automated flow-based detection system that provides objective, quantifiable measurements. This substitution improves productivity by ensuring consistent quality determination, reducing defects, and eliminating the need for reinspection, despite the increased device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The device accurately detects the adhesive flow rate and determines bonding defects, preventing defective batteries from progressing to subsequent processes, thereby enhancing manufacturing efficiency and consistency.

Implementation Method 1

a flow sensor detecting a flow rate of an adhesive supplied to the injecting portion

Methodology Applied

Scientific EffectUltrasonic wave: Ultrasound

Implementation Method 2

a flow sensor may calculate a flow velocity of an adhesive based on a difference between a reception time of a first ultrasonic wave received by a second transceiver portion and a reception time of a second ultrasonic wave received by a first transceiver portion

Methodology Applied

Scientific EffectTime of flight: Time of Flight

Data Source

PatentUS20250023008A1Battery bonding device

Publication Date: 2025.01.16 SK ON CO LTD

AI summary

A battery bonding device according to the present disclosure includes an injection portion discharging an adhesive to bond an electrode assembly, a flow sensor detecting a flow rate of an adhesive supplied to the injecting portion, and a control portion determining whether the electrode assembly is defective according to the flow rate.