Through-transmission Eddy Current Inspection for Power Source Electrodes
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Solution Overview
Problem
Existing methods for detecting the thickness and defects of electrode film materials during manufacturing are invasive, slow, costly, and unable to provide real-time feedback.
Innovation Solution
An eddy current non-destructive evaluation system that uses a pair of coils to generate and receive electromagnetic fields, allowing for the determination of electrode film material thickness and defect detection in a non-contact, high-speed manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional invasive methods are used to detect thickness and defects of electrode film materials, then measurement accuracy can be achieved, but the detection speed is slow and real-time feedback is unavailable
Solution Approach 1:
The patent replaces traditional mechanical contact-based thickness measurement methods with electromagnetic field-based eddy current detection. The system uses transmit and receive coils to generate and detect electromagnetic fields that interact with the electrode film material, enabling non-contact, high-speed thickness and defect detection without mechanical contact, thus achieving both high speed and high precision simultaneously
Solution Approach 2:
The patent introduces electromagnetic fields as an intermediary between the detection system and the electrode film material. The transmit coil generates electromagnetic fields that penetrate the material, and the receive coil detects the modified fields, providing real-time information about thickness and defects without direct mechanical contact, thereby enabling high-speed non-destructive evaluation
2Productivity
If traditional detection methods are used, then detailed defect information can be obtained, but the detection process is invasive and slows down manufacturing
Solution Approach 1:
The patent replaces invasive mechanical detection methods with non-contact electromagnetic field-based eddy current detection. The transmit and receive coils generate and detect electromagnetic fields that interact with the electrode film material without physical contact, eliminating mechanical intrusion while maintaining detailed defect detection capability, thus enabling high-speed non-destructive evaluation that does not slow down manufacturing
Solution Approach 2:
The electromagnetic fields generated by the transmit coil naturally interact with the electrode film material properties (conductivity, thickness, defects), and the receive coil passively detects these interactions. The material itself provides the detection signal through its electromagnetic response, eliminating the need for external mechanical probing or sampling that would slow down production
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
The system enables accurate measurement of thickness and defect detection with high line-speed, providing real-time feedback and improving manufacturing efficiency.
Implementation Method 1
a first coil disposed adjacent the electrode film material and configured to operate in a transmit mode, and, based on the transmission signal, to generate an electromagnetic field that passes through the electrode film material
Implementation Method 2
a second coil disposed adjacent and on an opposite side of the electrode film material as the first coil and configured to operate in a receive mode. The second coil is configured to generate a first electromagnetic field voltage based on the electromagnetic field
Implementation Method 3
Through-transmission eddy current system for inline inspection of power source electrodes
Data Source
AI summary
An eddy current non-destructive evaluation system for an electrode film material includes: at least one control module configured to generate a transmission signal; and a first pair of coils. The first pair of coils includes: a first coil disposed adjacent the electrode film material and configured to operate in a transmit mode, and, based on the transmission signal, to generate an electromagnetic field that passes through the electrode film material; and a second coil disposed adjacent and on an opposite side of the electrode film material as the first coil and configured to operate in a receive mode. The second coil is configured to generate a electromagnetic field voltage based on the electromagnetic field. The at least one control module is configured, based on the electromagnetic field voltage, to at least one of determine a thickness of the electrode film material and detect a defect of the electrode film material.