Electrode Groove Detection for Battery Thickness Uniformity

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Solution Overview

Problem

Secondary batteries face performance degradation due to non-uniform coupling surfaces between electrodes and separators, leading to increased electrolyte consumption and swelling, which can be caused by weakened bonding strength or thickness irregularities.

Innovation Solution

A detection device with a measurement module and processor is used to measure electrode thickness, identifying grooves and comparing them to a reference shape to determine defective electrodes that may form gaps in the assembly, ensuring uniform bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If electrode and separator are coupled by heat and pressure, then bonding strength is improved, but non-uniform thickness and gaps may still form due to electrode defects

Engineering Contradiction:

Improvebonding strengthVSAvoidthickness uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The detection device measures electrode thickness and identifies grooves before the electrode is coupled with the separator, allowing defective electrodes to be detected and removed in advance, preventing gap formation during assembly

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces mechanical inspection methods with an optical measurement system that uses light to detect electrode thickness and identify grooves, enabling more precise detection of electrode defects

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If electrode thickness is non-uniform, then coupling surface uniformity deteriorates, but detecting and removing defective electrodes requires additional measurement and processing

Engineering Contradiction:

Improvecoupling surface uniformityVSAvoiddetection system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The detection device integrates multiple functions into a single system: it measures electrode thickness, identifies groove locations, determines groove depth, and classifies electrodes as defective or normal, eliminating the need for separate inspection devices

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system automatically processes thickness measurement data to identify grooves and classify electrodes without requiring manual intervention, reducing operational complexity while maintaining high detection accuracy

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20260022936A1Detection device configured to detect failure of electrode and method of operating the same

Publication Date: 2026.01.22 LG ENERGY SOLUTION LTD

AI summary

Detection devices and methods for detection devices are provided. The detection devices may include a measurement module configured to measure a thickness of at least one electrode; and a processor electrically connected to the measurement module, wherein the processor may be configured to: determine whether the at least one electrode includes a groove based on the measured thickness of the at least one electrode; and determine whether the at least one electrode is a defective electrode based on a comparison between the groove in the at least one electrode and a reference shape, such that the groove in the at least one electrode corresponds to a wave-shaped groove.