Electrochemical Process Manifolds for Faster Battery Defect Detection
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Solution Overview
Problem
Battery cell manufacturing processes face low yields and time-consuming formation and aging processes, with current solutions becoming cost-prohibitive at scale, and existing methods struggle to efficiently detect defects in a high-volume setting.
Innovation Solution
The development of an electrochemical process manifold (EPM) system that controllably adjusts current or voltage during battery cell formation, integrating voltage-hours and current measurements over time to create a data-driven diagnostic tool for improving yield and identifying defects, which is stored in a non-transitory computer-readable memory medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional battery cell formation and aging processes are used, then cells can be manufactured, but the processes are time-consuming and yields are below 80%
Solution Approach 1:
The patent applies preliminary action by performing formation processes at elevated temperatures (e.g., 45°C to 85°C) before standard aging procedures. This pre-treatment accelerates electrochemical reactions and stabilizes cell characteristics early in the manufacturing process, reducing subsequent aging time while improving yield by identifying defective cells earlier through enhanced measurement sensitivity during the accelerated formation phase.
2Productivity
If more equipment and infrastructure are deployed to handle high-volume cell production, then production capacity increases, but costs become prohibitive
Solution Approach 1:
The patent implements multi-functionality by designing measurement and control systems that serve multiple purposes: they monitor cell voltage and temperature during formation, detect defective cells through anomaly analysis, and provide data for process optimization. This single integrated system replaces what would traditionally require separate equipment for formation monitoring, quality inspection, and process control, reducing capital expenditure while maintaining high-volume production capability.
3Measurement precision
If traditional defect detection methods are used during aging, then defects can be identified, but the process takes days to complete
Solution Approach 1:
The patent applies periodic action by implementing continuous or frequent measurements during the accelerated formation process, rather than relying on infrequent checks during extended aging periods. The system periodically samples voltage, current, and temperature data at elevated temperatures where defect manifestations are more pronounced, enabling rapid identification of defective cells within hours rather than days, while maintaining high detection accuracy through statistical analysis of the periodic measurement data.
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 approach enhances battery cell formation efficiency, reduces defect detection time, and improves overall yield by dynamically monitoring and controlling the formation process, enabling early identification and removal of defective cells, thus optimizing production efficiency and reducing costs.
Implementation Method 1
the current through the cell (or the voltage across the cell) is controllably adjusted to charge or discharge the cell
Implementation Method 2
the voltage across the cell is measured and integrated over time to obtain a voltage-hours value for each time step
Data Source
AI summary
Systems, methods and devices for constructing an electrochemical process manifold (EPM) for a battery cell during a formation process. The current through the cell is controllably adjusted to charge or discharge the cell. The temperature and/or pressure may be controllably adjusted along with the current. At each of a plurality of time steps as the current is controllably adjusted, the voltage across the cell is measured and integrated over time to obtain a voltage-hours value for each time step. A data point is stored in memory for each time step that includes the measured voltage, the voltage-hours value, and the current through the cell at the respective time step. The data points for each time step are mapped onto an EPM, and the EPM is stored in a non-transitory computer-readable memory medium.