Electrolyte Injection Control Using Vacuum Air Measurement
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Solution Overview
Problem
Existing rechargeable battery manufacturing processes face challenges in accurately determining the optimal amount of electrolyte to inject, leading to potential electrolyte overflow or insufficient filling, which can contaminate the case and reduce battery lifespan.
Innovation Solution
An electrolyte injection device with a vacuum pump, air sensor, and control system that measures exhaust air to calculate and control the precise amount of electrolyte needed based on the internal space volume, ensuring a maximum suitable injection without overflow or lack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a predetermined amount of electrolyte is injected into the case, then the injection process is simple and fast, but the electrolyte may overflow or be insufficient due to variations in internal space volume
Solution Approach 1:
The vacuum pump performs preliminary action by exhausting the internal space of the case before electrolyte injection. This creates a vacuum state that allows precise measurement of the internal volume through exhaust air quantity, enabling accurate determination of the required electrolyte injection amount before the actual injection occurs.
Solution Approach 2:
The air sensor provides feedback by measuring the exhaust air quantity during the vacuum exhaustion process. This measurement is fed back to the control portion, which calculates the precise electrolyte injection amount based on the measured internal space volume, ensuring accurate injection without overflow or insufficiency.
2Reliability
If the injection amount is increased to ensure sufficient electrolyte, then electrolyte lack is prevented, but electrolyte overflow and case contamination occur
Solution Approach 1:
The system performs preliminary measurement of the internal space volume by exhausting air with the vacuum pump before injection. This preliminary action determines the exact amount of electrolyte needed, preventing both overflow and insufficiency by matching the injection amount to the actual internal volume.
Solution Approach 2:
The air sensor measures the exhaust air quantity and provides feedback to the control portion. This feedback mechanism enables real-time adjustment of the injection amount based on the measured internal space, ensuring that the electrolyte injection is neither excessive nor insufficient.
3Object-generated harmful factors
If the injection amount is decreased to prevent overflow, then case contamination is reduced, but electrolyte insufficiency and shortened battery lifespan occur
Solution Approach 1:
The vacuum exhaustion process performs preliminary measurement of the internal space volume before electrolyte injection. This allows the system to determine the precise injection amount that will fill the case completely without overflow, ensuring both overflow prevention and sufficient electrolyte for maximum battery lifespan.
Solution Approach 2:
The air sensor provides feedback on the exhaust air quantity, enabling the control portion to calculate the exact electrolyte injection amount needed. This feedback ensures that the injection amount is optimized to prevent overflow while guaranteeing sufficient electrolyte for long battery operation.
4Device complexity
If a fixed injection amount is used for all cases, then the manufacturing process is simple, but it cannot accommodate variations in internal space volume
Solution Approach 1:
The system performs preliminary measurement of each case's internal space volume through vacuum exhaustion before injection. This preliminary action enables the system to adapt to volume variations in each individual case while maintaining a relatively simple overall process structure.
Solution Approach 2:
The air sensor provides feedback on the exhaust air quantity for each case, allowing the control portion to automatically adjust the injection amount based on measured volume variations. This feedback mechanism enables adaptability to different case volumes without significantly increasing process complexity.
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 device ensures consistent and efficient electrolyte filling across batteries with varying internal volumes, preventing contamination and enhancing battery performance and lifespan.
Implementation Method 1
an exhaust module including a vacuum pump that is connected to the electrolyte injection pipe and configured to exhaust an internal space of the case
Implementation Method 2
an air sensor configured to measure an amount of an exhaust air of the case
Data Source
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AI summary
An electrolyte injection device includes: an electrolyte injection pipe that is configured to be coupled to an injection hole of a case; an exhaust module including a vacuum pump that is connected to the electrolyte injection pipe and is configured to exhaust an internal space of the case, and an air sensor configured to measure an amount of an exhaust air of the case; an electrolyte injection module including an electrolyte tank that is connected to the electrolyte injection pipe and is configured to store an electrolyte, and an injection nozzle installed at an inlet of the electrolyte tank; and a control portion that is electrically connected to each of the air sensor and the injection nozzle.