Electrode Sheet Positioning in ESA Using Optical-CT Alignment
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Solution Overview
Problem
Current methods for determining the position of electrode sheets in an electrode/separator assembly are limited by the inability to accurately capture and distinguish between indiscernible components in computed-tomographic (CT) data, leading to decreased placement accuracy and increased risk of short-circuits in battery cells.
Innovation Solution
A method that combines optical imaging with computed-tomography to determine the precise 3D position of electrode sheets, including their substrates and coatings, by aligning and scaling geometries from optical images with CT data, thereby accounting for indiscernible components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If computed-tomographic imaging methods are used to determine the position of electrode sheets, then 3D position information can be obtained, but certain materials (coating or substrate) do not provide CT contrast and remain indiscernible in the CT image
Solution Approach 1:
The patent combines optical imaging with computed-tomographic imaging to create a hybrid measurement system. Optical imaging captures the coating and substrate geometries that are indiscernible in CT data, while CT provides 3D position information for discernible components. The two imaging datasets are merged through geometric alignment and coordinate transformation to produce a complete position determination that accounts for all electrode sheet components including previously indiscernible ones.
2Reliability
If the anode is made larger circumferentially to implement complete overlay despite placement inaccuracies, then safety is improved, but material is wasted
Solution Approach 1:
The patent replaces the mechanical/measurement limitation of CT-only imaging with a combined optical-CT imaging system. This substitution enables precise measurement of placement accuracy for all electrode sheet components, including coatings and substrates that were previously indiscernible. With accurate position data, the stacking process can be optimized to reduce anode overhang while maintaining safety margins, eliminating the need to deliberately oversized the anode.
3Productivity
If the stacking process speed is increased to reduce bottleneck, then productivity is improved, but placement accuracy decreases
Solution Approach 1:
The patent implements preliminary optical imaging and indexing of electrode sheets before stacking. By capturing optical images and determining geometries in advance, the system prepares complete position information for all components. This preliminary action enables real-time monitoring and adjustment during high-speed stacking, allowing the process to maintain placement accuracy even at increased speeds by having all measurement data pre-available for rapid evaluation.
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 placement accuracy, process capability, and product quality by providing comprehensive geometry information for all components, reducing the risk of short-circuits and improving the efficiency of battery cell manufacturing.
Implementation Method 1
Optically imaging each electrode sheet at least in regions, in particular together with the uncoated contacting region of the substrate and the active region coated on both sides
Implementation Method 2
Computed-tomographically (CT) capturing at least one of the two components of the electrode sheets of the first type in the ESA and at least one of the two components of the electrode sheets of the second type in the ESA in a computed-tomographic image
Implementation Method 3
To manufacture cells, arrester contours must be cut into the continuous electrode foils. This is carried out with the aid of the so-called laser cutting process (notching)
Data Source
AI summary
A method for determining a position of electrode sheets in an electrode/separator assembly, the electrode sheets including a substrate and a bilateral coating of the substrate. The electrode sheets comprising at least one first and one second type of electrode sheets. Each electrode sheet is optically imaged, at least in regions, in one or multiple image regions. At least one region of a geometry of the substrate and at least one region of a geometry of the bilateral coating of the substrate is determined, based on the optical image. The electrode sheets are stacked to form an ESA. At least one of the two components of the electrode sheets of the first type is captured in the ESA and at least one of the two components of the electrode sheets of the second type in the ESA is captured in a computed-tomographic image.