Electrode Plate Inspection Using Separator-Guided Distance Sensing

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Solution Overview

Problem

The quality of electrode plates in batteries is critical for energy density and service life, but existing inspection methods fail to accurately assess the distance between sub-electrode plates, leading to potential wrinkling and performance issues during winding operations.

Innovation Solution

An electrode plate inspection device that combines a separator with sub-electrode plates, measures the distance between them using a color mark sensor, and determines qualification based on both distance and position accuracy, improving inspection accuracy and reducing misalignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the distance between sub-electrode plates is not accurately measured, then the inspection process is simple and fast, but the quality of the electrode plate deteriorates due to potential wrinkling and misalignment during winding operations

Engineering Contradiction:

Improvedistance measurement accuracy between sub-electrode platesVSAvoidinspection device structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A separator is introduced as an intermediary component between sub-electrode plates. The separator includes positioning structures that mediate the spacing relationship between plates, enabling accurate distance control without requiring complex direct measurement systems. The separator acts as a physical mediator that ensures proper positioning during assembly and inspection.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces complex mechanical measurement systems with optical sensing methods. Color mark sensors detect positioned marks on the electrode plate to determine sub-electrode plate positions and distances, substituting mechanical calipers or rulers with non-contact optical measurement, thereby improving accuracy while maintaining device simplicity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If multiple parameters are used to determine qualification, then the inspection accuracy is improved, but the inspection time and processing complexity increase

Engineering Contradiction:

Improveinspection accuracyVSAvoidinspection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

Positioning marks are pre-defined on the electrode plate during manufacturing. These color marks are placed at specific locations before inspection occurs. During inspection, the sensor only needs to detect these pre-positioned marks rather than performing complex calculations, significantly reducing inspection time while maintaining high measurement precision through multiple parameter evaluation.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If sub-electrode plates are combined with separator in advance, then misalignment during subsequent operations is reduced, but the manufacturing process complexity increases

Engineering Contradiction:

Improvealignment stabilityVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The separator is merged with the electrode plate assembly in advance during manufacturing. The separator integrates positioning structures that are combined with the electrode plate body, creating a unified component that maintains alignment stability throughout subsequent operations. This merging eliminates the need for separate alignment operations later in the process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Alignment and positioning operations are performed preliminarily during the assembly stage. The separator is positioned and fixed to the electrode plate before winding operations occur. This preliminary positioning action ensures that alignment is established early, preventing misalignment issues during subsequent winding and assembly operations.

Inventive Principle:

Principle #10Preliminary action

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

Enhances the quality of electrode plates by accurately determining their qualification, thereby improving battery performance and reducing the risk of wrinkling during winding, leading to higher energy density and extended service life.

Implementation Method 1

the sensor is a color mark sensor configured to obtain the position of the second sub-electrode plate by sensing a color between the first sub-electrode plate and a preset position

Methodology Applied

Scientific EffectColor sensing: Absorption Spectroscopy

Data Source

PatentUS20240429432A1Electrode plate inspection device and method, and winding device

Publication Date: 2024.12.26 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

AI summary

An electrode plate inspection device includes a combining unit configured to combine a separator on a side of a first electrode plate in a thickness direction of the first electrode plate, the first electrode plate including at least two sub-electrode plates arranged at intervals in a conveying direction of the first electrode plate; a measuring unit arranged downstream of the combining unit in the conveying direction, and configured to measure a first distance between two adjacent combined sub-electrode plates in the conveying direction; and a processing unit configured to determine whether the combined first electrode plate is qualified according to the first distance.