Flat Panel Detector Scintillator Tuning for Battery Defect Imaging
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Solution Overview
Problem
Existing battery detection methods suffer from low accuracy in detecting internal defects, particularly in larger batteries, due to insufficient precision in distinguishing differences between cathode and anode electrode plates, especially in corner regions and thick battery cells.
Innovation Solution
A battery detection apparatus with a flat panel detector having a scintillator layer thickness optimized to ensure density resolution less than 0.5%, combined with a radiation source and processor, to enhance detection precision and adapt to various battery sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the thickness of the scintillator layer is increased to improve detection capability for thicker batteries, then the density resolution improves, but the spatial resolution deteriorates
Solution Approach 1:
The patent applies parameter changes by optimizing the thickness of the scintillator layer to a specific range (0.3mm to 0.8mm) that balances density resolution and spatial resolution. This parameter optimization allows the detector to achieve sufficient density resolution for detecting internal defects in thicker batteries while maintaining adequate spatial resolution for accurate defect localization.
Solution Approach 2:
The patent implements local quality by using different scintillator layer thicknesses for different detection scenarios. Thinner scintillator layers (0.3mm-0.5mm) are used when spatial resolution is prioritized, while thicker layers (0.6mm-0.8mm) are used when density resolution is prioritized for thicker batteries. This localized optimization allows the system to adapt to different battery types and detection requirements.
2Device complexity
If manual visual inspection is used to detect internal defects, then the device complexity is low, but the measurement precision deteriorates
Solution Approach 1:
The patent replaces manual visual inspection with an automated X-ray detection system that uses a flat panel detector with optimized scintillator layer. This substitution of mechanical/manual detection with an automated imaging system dramatically improves measurement precision for detecting internal defects while maintaining reasonable device complexity through the use of standardized detector components.
3Adaptability or versatility
If the scintillator layer thickness is increased to detect larger batteries, then the detection capability for thick batteries improves, but the detection capability for small batteries deteriorates
Solution Approach 1:
The patent applies dynamics by making the scintillator layer thickness adjustable or selectable based on the battery size being detected. The system can dynamically adapt the detector configuration to match the detection requirements, using thicker scintillator layers for large/thick batteries and thinner layers for small batteries, thereby maintaining high detection accuracy across different battery sizes.
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
Improves the accuracy of detecting internal defects in batteries by enhancing the detection capabilities of the flat panel detector, allowing for more precise recognition of overhang and gap measurements between electrode plates, thus increasing the efficiency and reliability of battery production.
Implementation Method 1
the flat panel detector includes a scintillator layer, and a thickness of the scintillator layer is greater than a first preset thickness
Implementation Method 2
the radiation source emits a detection radiation in a direction toward the battery to be detected. The flat panel detector is located on the other side of the carrying assembly distal to the radiation source, where the flat panel detector is configured to receive the detection radiation that is emitted by the radiation source and penetrates the battery to be detected
Data Source
AI summary
A battery inspection apparatus comprises a bearing assembly, a ray source, and a flat panel detector; the bearing assembly is used for bearing a battery under test, the ray source is located at one end of the bearing assembly, and the direction in which a detection ray of the ray source is emitted faces the battery under test; the flat panel detector is located at the other end of the bearing assembly distant from the ray source, the flat panel detector is used for receiving a detection ray that is emitted by the ray source and penetrates through the battery under test, the flat panel detector comprises a scintillator layer, and the thickness of the scintillator layer is greater than a first preset thickness, so that the density resolution of the flat panel detector is less than 0.5%.