Battery Electrode Stack Position Verification Using X-Ray Edge Checks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery stacking machines lack sufficient placement accuracy, leading to potential short circuits and reduced chemical performance due to inadequate tolerance management, resulting in increased material consumption and production costs.
Innovation Solution
A method involving optical and X-ray based inspections to determine and verify the geometric positions of battery element layers, using a combination of top-down imaging and perpendicular X-ray irradiation to ensure precise stacking within defined tolerances, thereby preventing short circuits and optimizing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the separator and anode are dimensioned larger than the cathode to create a protrusion, then short circuit prevention is improved, but material consumption and production costs increase
Solution Approach 1:
The patent applies preliminary action by performing geometric determination and positional verification of battery element layers before final assembly. Optical images and X-ray data are collected in advance to calculate edge distances and assess short circuit risks, allowing proactive adjustment of stacking parameters without requiring excessive material protrusion for safety margins.
Solution Approach 2:
The patent changes parameters by using measured geometric data and positional information to dynamically calculate edge distances between layers. This replaces the static approach of fixed protrusion dimensions with a dynamic parameter-based system that optimizes material usage while maintaining safety, allowing precise control of layer positioning within tolerance ranges.
2Reliability
If the separator and anode are dimensioned larger than the cathode to create a protrusion, then short circuit prevention is improved, but production costs increase
Solution Approach 1:
The patent performs preliminary geometric determination and positional verification using optical imaging and X-ray methods before assembly. This advance measurement allows accurate calculation of edge distances and assessment of short circuit risks, enabling precise stacking that reduces material waste and lowers production costs while maintaining safety.
Solution Approach 2:
The patent replaces mechanical trial-and-error stacking with an automated measurement and calculation system. Optical cameras and X-ray devices automatically capture geometric data, and a computing device calculates edge distances and positioning accuracy, substituting manual measurement and adjustment with automated optical and radiographic systems that improve precision and reduce costs.
3Reliability
If stacking machine placement accuracy is increased, then short circuit prevention is improved, but device complexity and production costs increase
Solution Approach 1:
The patent implements feedback by measuring the actual geometric positions of battery element layers using optical imaging and X-ray methods, then using this measured data to verify whether edge distances meet safety requirements. This feedback loop allows validation of stacking accuracy without requiring excessively complex machines, as the verification system compensates for moderate machine precision limitations.
Solution Approach 2:
The patent replaces complex high-precision mechanical stacking systems with a combination of standard stacking equipment and post-stack measurement verification. Instead of relying solely on mechanical precision, the system uses optical cameras and X-ray devices to measure actual positions and calculate edge distances, substituting mechanical complexity with measurement and calculation-based verification.
4Manufacturing precision
If optical and X-ray based inspections are implemented, then manufacturing precision verification is improved, but device complexity increases
Solution Approach 1:
The patent merges optical imaging and X-ray inspection methods into a unified measurement system. Both techniques are used to capture geometric data of battery element layers, and their results are integrated by the computing device to calculate edge distances and verify positioning accuracy. This combination leverages the complementary strengths of both methods while sharing common data processing infrastructure.
Solution Approach 2:
The patent applies universality by using a single computing device and data processing framework to handle both optical image analysis and X-ray data evaluation. The same system calculates edge distances, determines positional accuracy, and assesses short circuit risks for both measurement modalities, reducing overall system complexity through shared functionality rather than separate dedicated systems.
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
Ensures accurate and efficient stacking of battery elements with minimal material waste, reducing production costs and ensuring optimal electrochemical performance by minimizing oversizing and enhancing positional accuracy.
Implementation Method 1
geometries of at least one of the large areas of at least (all) anodes and/or (all) cathodes, and optionally also of the separators, are determined
Implementation Method 2
the stack is irradiated with X-rays emitted by an X-ray source and detected by an X-ray detector, wherein the X-rays are directed perpendicular to the large surfaces of the battery element layers
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
Method for testing a stack (1) of several battery element layers in the form of anodes (2a), cathodes (2b) and separators (3), wherein: • geometries of at least one of the large surfaces of at least the anodes (2a) and/or the cathodes (2b) are determined, • the battery element layers are stacked to form the stack (1), • subsequently, for a positional check of the anodes (2a) and/or the cathodes (2b), - the stack (1) is irradiated with X-rays (9), wherein the X-rays (9) are directed perpendicular to the large surfaces of the battery element layers, and, using the detected X-rays, the largest edge distance between the edges of the electrode type (anodes or cathodes) of at least one pair of opposite sides of the stack (1) is determined, - it is checked whether this largest edge distance is smaller than a first tolerance value.where ∘ in the negative case the stack (1) is evaluated as inadmissible and ∘ in the positive case ▪ the protrusion is defined as half the value by which the largest edge distance is smaller than the first tolerance value and ▪ it is checked whether the largest edge distance is smaller than a value resulting from the sum of the shortest dimension with respect to the direction of determination of all the electrodes (2) under consideration on the one hand and the difference of a second tolerance value and half the protrusion on the other hand, where - in the negative case the stack (1) is evaluated as inadmissible and - in the positive case the stack (1) is evaluated as admissible.