Battery Module Qualification Using Outlier Screening and Flash Thermography

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Solution Overview

Problem

Existing methods for detecting defects in battery modules are inadequate in identifying deviations in measured parameters of battery cell arrays, which can lead to inefficient qualification and potential failures in battery performance.

Innovation Solution

A method involving a battery module functionality test, followed by a focused secondary test using statistical analysis and flash thermography to assess weld quality, ensuring that battery cell arrays meet predetermined thresholds, and a system with a controller to perform these tests and qualify the battery module based on the results.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a comprehensive battery module functionality test is performed on all battery cell arrays, then measurement precision and reliability are improved, but device complexity and time consumption increase

Engineering Contradiction:

Improvedefect detection precisionVSAvoidtesting system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The testing process is segmented into two stages: a primary functionality test applied to all battery cell arrays to identify outliers, and a focused secondary test applied only to identified outliers using flash thermography. This segmentation reduces overall system complexity while maintaining high detection precision by concentrating advanced testing resources only where needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different testing qualities to different parts of the battery module. Most battery cell arrays receive a standard functionality test, while only identified outlier arrays receive the more sophisticated flash thermography secondary test. This local differentiation optimizes resource allocation and reduces overall complexity while maintaining high detection precision for defective areas.

Inventive Principle:

Principle #3Local quality

2Reliability

If a comprehensive battery module functionality test is performed on all battery cell arrays, then reliability is improved, but time consumption increases

Engineering Contradiction:

Improvebattery module reliabilityVSAvoidqualification time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The testing process is divided into a rapid primary functionality test for all arrays and a time-intensive secondary flash thermography test only for identified outliers. This segmentation maintains high reliability by thoroughly testing suspicious areas while minimizing total time consumption by avoiding exhaustive testing of all arrays.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of performing comprehensive secondary testing on all battery cell arrays, the patent applies partial action by conducting the focused secondary flash thermography test only on identified outliers. This approach maintains reliability for critical defect detection while significantly reducing time consumption compared to universal testing.

Inventive Principle:

Principle #16Partial or excessive action

3Measurement precision

If statistical analysis and flash thermography are used for focused secondary testing, then measurement precision is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improveweld defect detection precisionVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The manufacturing process is segmented into a simple primary functionality test that is easy to manufacture and implement, followed by an advanced secondary flash thermography test with statistical analysis applied only to identified outliers. This segmentation maintains manufacturing simplicity for the majority of production while achieving high measurement precision for defect detection where needed.

Inventive Principle:

Principle #1Segmentation

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

Effectively identifies outliers and assesses weld quality, ensuring the battery module's reliability and performance by performing a comprehensive analysis of battery test data and focused secondary tests, thereby improving the qualification process and reducing potential failures.

Implementation Method 1

the focused secondary test includes performing a flash thermography by applying a flash of light to a target area including one of the battery cell arrays with the measured parameter that deviates from the predetermined threshold and capturing at least one image of the target area with an imaging camera to assess a welds in the target area

Methodology Applied

Scientific EffectFlash thermography: Thermal Radiation

Implementation Method 2

the secondary test includes directing at least one of an optical sensor or an ultrasound at the target area

Methodology Applied

Scientific EffectUltrasound: Ultrasound

Data Source

PatentUS20250096339A1System and method for assessing a battery module

Publication Date: 2025.03.20 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method that includes performing a battery module functionality test on battery cell arrays within the battery module to obtain battery test data for each of the battery cell arrays. The battery test data is used to determine if a measured parameter for one of the battery cell arrays deviates from a predetermined threshold for the measured parameter. A focused secondary battery test is performed on each of the battery cell arrays having the measured parameter that deviates from the predetermined threshold. The battery module is then qualified based on at least one of the battery test data and the focused secondary battery test.