Battery Cell Foil Breakage Detection from Early Resistance Shift
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Solution Overview
Problem
Existing methods for detecting foil breakage in battery cells during the battery formation process require additional inspection processes that temporarily halt production, making it difficult to accurately measure internal resistance and delta internal resistance, especially before the battery cells are fully formed.
Innovation Solution
An early diagnosis apparatus and method that measures internal resistance of battery cells during a pause period between the assembly and formation processes, calculating delta internal resistance to detect foil breakage using a resistance measurer and foil breakage inspector, allowing for early detection before the formation process stabilizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an additional inspection process is added in the middle of the battery formation process to detect foil breakage, then foil breakage detection capability is improved, but production efficiency deteriorates due to temporary line stoppage
Solution Approach 1:
The patent performs foil breakage inspection during the pause period between battery assembly and formation processes, before the formation process fully commences. By measuring internal resistance at this early stage when current paths are not yet fully established, the system detects foil breakage before production continues, eliminating the need to halt the formation process for inspection while maintaining detection capability
Solution Approach 2:
The inspection process is integrated into the existing pause period between assembly and formation processes without requiring additional production halts. The resistance measurement occurs continuously during this natural transition period, maintaining production flow while performing the inspection function
2Reliability
If foil breakage inspection is performed during the battery formation process, then foil breakage detection is enabled, but measurement accuracy deteriorates due to temporary current path formation
Solution Approach 1:
The patent performs resistance measurement during the pause period before the formation process begins, when temporary current paths have not yet formed. This timing captures the electrical characteristics of the battery cells in a stable state, providing accurate baseline measurements for foil breakage detection without interference from formation process current paths
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 detection of foil breakage during the early stages of the battery formation process, preventing production halts and improving detection accuracy, with a detection power of 91.50% compared to 36% in existing methods.
Implementation Method 1
a resistance measurer configured to measure an internal resistance of each of a plurality of battery cells
Data Source
AI summary
An early diagnosis apparatus for foil breakage of a battery, the early diagnosis apparatus includes a resistance measurer configured to measure an internal resistance of each of a plurality of battery cells included in a battery tray output from a battery assembly process when a point in time of an inspection start is reached after battery assembly is completed, during a pause period between a battery assembly process and a battery formation process, and a foil breakage inspector configured to calculate a delta internal resistance, based on the internal resistance received from the resistance measurer, and to inspect whether foil breakage is present in each of the plurality of battery cells, based on the delta internal resistance.