Battery Electrode Stack Position Checking With X-Ray Edge Spacing
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Solution Overview
Problem
Current battery stacking methods require significant material overdimensioning to prevent short circuits due to placement inaccuracies, leading to increased costs, space requirements, and weight, necessitating improved placement accuracy and quality assurance.
Innovation Solution
A method involving optical camera systems for initial geometry determination and X-ray radiation for precise edge spacing checks, allowing for quick and cost-effective assessment of battery element layer positioning, ensuring sufficient tolerance compliance without excessive overdimensioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery element layers are overdimensioned to avoid short circuits due to placement inaccuracies, then reliability is improved, but material consumption increases
Solution Approach 1:
The patent replaces mechanical measurement systems with optical detection (camera systems) and X-ray radiation detection to measure battery element layer positions. This substitution enables precise measurement without physical contact, allowing for accurate detection of edge spacings and placement accuracy, thereby reducing the need for excessive material overdimensioning while maintaining reliability
Solution Approach 2:
The patent creates optical copies (images) of the battery element layers using camera systems and X-ray detection. These copies allow for precise measurement and analysis of layer positions and edge spacings without physically manipulating or adding material to the layers, enabling accurate quality control with minimal material consumption
2Reliability
If battery element layers are overdimensioned to ensure optimal electrochemical performance, then performance is improved, but weight increases
Solution Approach 1:
The patent uses optical and X-ray detection systems to precisely measure battery element layer positions and dimensions. This non-contact measurement approach enables accurate determination of the minimum required layer dimensions for optimal electrochemical performance, eliminating the need for excessive overdimensioning and thereby reducing stack weight
Solution Approach 2:
By creating optical copies of the battery element layers through camera and X-ray detection, the patent enables precise virtual measurement and analysis. This allows for optimization of layer dimensions to achieve optimal electrochemical performance without adding unnecessary material weight
3Reliability
If battery element layers are overdimensioned to account for placement inaccuracies, then reliability is improved, but space requirements increase
Solution Approach 1:
The patent employs optical camera systems and X-ray detection to precisely measure the positions and dimensions of battery element layers. This enables accurate determination of the minimum required spacing between layers to prevent short circuits, reducing the need for excessive overdimensioning and thereby minimizing stack area requirements
Solution Approach 2:
The patent creates optical copies of the battery element layers to enable precise virtual measurement of edge spacings and layer positions. This allows for optimization of layer dimensions and spacing to ensure reliable short circuit prevention without increasing the overall stack area
4Manufacturing precision
If placement accuracy of stacking machines is increased to minimize overdimensioning, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical precision mechanisms with optical detection systems (cameras and X-ray detectors). These detection systems measure battery element layer positions and dimensions with high precision after stacking, enabling accurate quality control without requiring excessively complex stacking machine mechanisms
Solution Approach 2:
The patent creates optical copies of the stacked battery elements using camera and X-ray detection systems. These copies enable precise measurement and verification of placement accuracy, allowing for high manufacturing precision to be achieved and verified through detection rather than through complex mechanical stacking mechanisms
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 method enables rapid and accurate verification of battery stack positioning, reducing material waste and costs while ensuring reliable electrochemical performance by linking geometric data with X-ray determination results, thus enhancing the efficiency of battery manufacturing.
Implementation Method 1
the stack is irradiated by X-ray radiation that is emitted by an X-ray emitter and detected by an X-ray detector
Data Source
AI summary
A method for checking a stack of multiple battery element layers in the form of anodes, cathodes, and separators. Geometries of at least one of the large surfaces of at least the anodes and/or the cathodes are determined. The battery element layers are stacked to form the stack. Subsequently for a position check of the anodes and/or of the cathodes, the stack is irradiated by X-ray radiation), wherein the X-ray radiation is oriented perpendicularly with respect to the large surfaces of the battery element layers, and via the detected X-ray radiation, with regard to at least one pair of opposite sides of the stack the greatest edge spacing that is present between the edges of the considered type of electrode (anodes or cathodes) of this pair is determined.