Battery Electrode Coating Evenness Detection
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Solution Overview
Problem
Existing methods for evaluating the evenness of a compound coated on a battery electrode, such as those using x-ray measurements, cannot distinguish between unevenness caused by thickness changes or material mixing ratios, leading to poor resolution and quality control issues in electrode performance.
Innovation Solution
A detecting apparatus employing a combination of an ultrasonic through beam sensor for measuring mass per unit area and a laser displacement meter for measuring thickness, allowing for simultaneous evaluation of evenness based on calculated coated density, which compares measured values against thresholds to assess the evenness of the compound coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If x-ray measurement is used to evaluate compound evenness, then measurement can be performed, but resolution is poor and inability to distinguish between thickness variation and material mixing ratio variation occurs
Solution Approach 1:
The measurement is segmented into two independent components: thickness measurement (via laser displacement meter) and mass per unit area measurement (via ultrasonic sensor). This segmentation allows separate evaluation of thickness variation and material density variation, preventing information loss about the cause of unevenness.
Solution Approach 2:
The patent introduces an intermediary calculation step where coated density is computed from the measured mass per unit area and thickness. This intermediary parameter serves as a mediator that connects the two measurements and enables identification of whether unevenness originates from thickness changes or material mixing ratio changes.
2Device complexity
If single parameter measurement is used, then measurement simplicity is maintained, but ability to identify cause of unevenness is lost
Solution Approach 1:
The measurement system is segmented into two independent measurement channels: one for thickness (laser displacement meter) and one for mass per unit area (ultrasonic sensor). This segmentation increases device complexity but preserves complete information about the compound's physical state, enabling identification of unevenness causes.
Solution Approach 2:
The patent combines two different measurement technologies (ultrasonic sensing and laser displacement measurement) into a composite measurement system. This composite approach integrates complementary measurement capabilities, allowing simultaneous acquisition of mass per unit area and thickness data without information loss.
3Reliability
If x-ray measurement is used, then evenness can be detected, but quality control effectiveness is reduced due to poor resolution
Solution Approach 1:
The patent replaces the x-ray measurement system with a combination of ultrasonic through-beam sensing and laser displacement measurement. This substitution eliminates the resolution limitations of x-ray measurement while providing superior measurement precision for both thickness and mass per unit area, thereby enhancing quality control reliability.
Solution Approach 2:
The patent changes the measurement parameters from single-parameter x-ray attenuation to dual-parameter measurement (mass per unit area and thickness). This parameter change enables more precise evenness evaluation and identification of unevenness causes, significantly improving measurement precision and quality control effectiveness.
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
This approach enables precise evaluation of the compound's evenness, reducing performance variation in batteries by identifying the cause of unevenness and providing feedback for improved manufacturing processes.
Implementation Method 1
a first sensor for measuring a mass per unit area of any part of the compound, preferably an ultrasonic through beam sensor
Implementation Method 2
a second sensor for measuring a thickness of any part of the compound, preferably a laser displacement meter
Data Source
AI summary
The objective of the present invention is to provide an unexpected detecting apparatus enabled to evaluate an evenness of a compound coated on an electrode of a battery. The detecting apparatus (1) detects an evenness of a compound (12) coated on an electrode (10) of a battery, and includes a first sensor (20) for measuring a mass per unit area of the compound (12) in any points thereof, a second sensor (30, 50) for measuring a thickness of the compound (12) in the any points, and a holder (40, 60) for holding the first and second sensors (20, 30, 50), in which the first and second sensors (20, 30, 50) measure the mass and thickness at the same time, and the evenness is evaluated on the basis of the measured mass and thickness.