Flat Panel Detector Scintillator Thickness for Battery Defect Imaging
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Solution Overview
Problem
Existing battery detection methods, particularly for larger batteries, suffer from low accuracy in detecting internal defects such as the gap and overhang of electrode plates due to insufficient precision, especially in corner regions and thick batteries.
Innovation Solution
A battery detection apparatus with a flat panel detector having a scintillator layer thickness optimized to ensure a density resolution less than 0.5%, combined with a radiation source and processor, to enhance detection accuracy and adapt to various battery sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection is used to detect internal defects, then the detection method is simple, but the detection accuracy is low
Solution Approach 1:
The patent replaces manual visual inspection with an automated X-ray detection system. The radiation source emits X-rays that penetrate the battery, and the flat panel detector captures the transmitted radiation to generate images of internal structures. This substitution of mechanical/manual inspection with automated imaging technology significantly improves detection accuracy while maintaining manageable system complexity through standardized components.
Solution Approach 2:
The patent introduces X-ray radiation as an intermediary to detect internal battery defects. The radiation penetrates through the battery housing and internal components, allowing visualization of electrode plates, separators, and other internal structures without direct physical contact or disassembly of the battery.
2Measurement precision
If the scintillator layer thickness is increased to improve density resolution, then the density resolution improves, but the spatial resolution deteriorates
Solution Approach 1:
The patent optimizes the scintillator layer thickness to a specific range (0.3mm to 0.7mm) to achieve the best balance between density resolution and spatial resolution. This parameter optimization allows the detection system to resolve density differences as small as 0.5% while maintaining sufficient spatial detail to identify internal battery defects. The optimized thickness ensures adequate X-ray absorption for high contrast imaging without excessive blurring that would compromise spatial resolution.
3Quantity of substance
If the battery size is increased to meet application requirements, then the battery capacity increases, but the detection accuracy for internal defects decreases
Solution Approach 1:
The patent adjusts the scintillator layer thickness parameter based on battery size and thickness. For larger batteries with greater thickness, the optimized scintillator thickness (0.3mm to 0.7mm) provides sufficient X-ray absorption and contrast enhancement to maintain detection accuracy. This parameter optimization compensates for the increased path length through larger batteries, ensuring consistent defect detection capability across different battery sizes and capacities.
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 detection of internal defects in batteries by increasing the density and spatial resolution, enabling more precise recognition of electrode plate positions and states, thus enhancing the accuracy and efficiency 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, such that a density resolution of the flat panel detector is less than 0.5%
Implementation Method 2
the radiation source emits a detection radiation in a direction toward the battery to be detected
Data Source
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AI summary
A battery inspection apparatus (400), a flat panel detector (430), and a battery production device. The battery inspection apparatus (400) comprises a bearing assembly (410), a ray source (420), and a flat panel detector (430); the bearing assembly (410) is used for bearing a battery under test (100), the ray source (420) is located at one end of the bearing assembly (410), and the direction in which a detection ray of the ray source (420) is emitted faces the battery under test (100); the flat panel detector (430) is located at the other end of the bearing assembly (410) distant from the ray source (420), the flat panel detector (430) is used for receiving a detection ray that is emitted by the ray source (420) and penetrates through the battery under test (100), the flat panel detector (430) comprises a scintillator layer (431), and the thickness of the scintillator layer (431) is greater than a first preset thickness, so that the density resolution of the flat panel detector (430) is less than 0.5%.