Secondary Battery Sealer Gap Prediction via Thermal Expansion
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Solution Overview
Problem
Existing methods for sealing secondary batteries struggle to accurately measure and manage the gap of the sealer in a non-visible region during the sealing process, leading to inefficiencies and quality control issues.
Innovation Solution
A method that involves using a camera and temperature sensor to predict thermal expansion of the sealer in a non-visible region by obtaining shape and temperature information, allowing for adjustment of the sealer gap during the sealing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a camera is used to photograph the sealer for gap measurement, then in-line measurement capability is improved, but the measurement is impossible in the non-visible region covered by the heater
Solution Approach 1:
The patent introduces thermal expansion data as an intermediary that connects the measurable temperature information with the unmeasurable gap dimension. By using the thermal expansion coefficient and temperature rise data, the system calculates the thermal deformation amount, which serves as a mediator to infer the gap change in the heater-covered region without direct optical measurement
Solution Approach 2:
The patent replaces the direct optical measurement system with a thermal-mechanical calculation system. Instead of using a camera to directly photograph the gap in the non-visible region, the system substitutes this with temperature measurement followed by thermal expansion calculation, converting an optical measurement problem into a thermal-mechanical computation problem
2Reliability
If total inspection is performed to check sealing quality, then product quality reliability is improved, but material, human, and time losses increase
Solution Approach 1:
The patent enables the sealing process to self-monitor its own quality parameters through integrated temperature sensing and thermal expansion calculation. The system automatically tracks the thermal deformation of the sealer during the sealing process, providing real-time quality data without requiring external inspection processes, thus eliminating the need for separate total inspection operations
Solution Approach 2:
The patent implements a feedback mechanism where temperature measurement data is continuously monitored, thermal expansion is calculated in real-time, and this information is fed back to assess sealing quality. This closed-loop feedback system allows for immediate quality assessment during production, replacing the open-loop total inspection approach that requires stopping production for sampling and measurement
3Ease of manufacture
If the sealer gap is not adjusted for thermal expansion, then the sealing process is simpler, but the sealing thickness precision deteriorates
Solution Approach 1:
The patent dynamically adjusts the sealer gap parameter based on measured temperature changes and calculated thermal expansion. Instead of using a fixed mechanical gap setting, the system modifies the effective gap parameter in response to thermal conditions, allowing the sealing process to adapt to thermal deformation and maintain precise sealing thickness despite the added measurement and calculation steps
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 reliable prediction and management of sealer gap on an in-line basis, improving process efficiency and sealing reliability.
Implementation Method 1
heating the electrode lead with the heater
Implementation Method 2
acquiring thermal expansion data according to the temperature of the sealer
Data Source
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AI summary
The present disclosure provides a method for sealing a secondary battery, which seals an electrode lead and a battery case of the secondary battery, the method comprising the steps of: providing a heater on a front surface of a sealer; providing the electrode lead between an upper sealer and a lower sealer contained in the sealer; heating the electrode lead with the heater; sealing the electrode lead and the battery case with the sealer; photographing the sealer around the heater with a camera disposed on a front surface of the heater to obtain shape information; measuring the temperature of the sealer around the heater with a temperature sensor to obtain temperature information; acquiring thermal expansion data according to the temperature of the sealer using the shape information, the temperature information, and the material information about the sealer; and measuring the temperature of the electrode lead with the temperature sensor and then predicting the thermal expansion value of the sealer at the electrode lead covered by the heater using the thermal expansion data.