Separator Roll Defect Inspection via Electromagnetic Wave Penetration
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Solution Overview
Problem
Existing defect inspection devices for separator rolls are inefficient as they require multiple devices for each separator produced, and cannot inspect for foreign objects trapped inside the roll after it is wound around a core, leading to increased production costs and potential short circuits in lithium-ion batteries.
Innovation Solution
A defect inspection device that uses a radiation source to emit electromagnetic waves capable of passing through the separator roll, allowing detection of foreign objects inside the roll using a sensor section, enabling inspection with a minimal number of devices and after the roll is wound.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple defect inspection devices are used for each separator produced by slitting, then inspection coverage is improved, but production cost increases
Solution Approach 1:
The electromagnetic wave-based inspection device is designed to inspect multiple separators simultaneously by positioning multiple separators between the radiation source and sensor. A single device performs the function of multiple devices, reducing overall system complexity and cost while maintaining comprehensive inspection coverage across all separators produced from slitting an original sheet
Solution Approach 2:
The patent combines multiple inspection functions into a single integrated device. By merging the inspection capability for multiple separators into one device, the system reduces the total number of devices required, thereby lowering production costs while ensuring reliable inspection coverage for all separators
2Measurement precision
If inspection is performed before winding separator around core, then foreign objects on surface are detected, but devices cannot detect foreign objects trapped inside the roll
Solution Approach 1:
The patent replaces mechanical contact-based inspection methods with electromagnetic wave-based detection. Electromagnetic waves can penetrate the wound separator roll structure, enabling detection of foreign objects both on the surface and trapped inside the roll without requiring physical contact or unwinding the separator
Solution Approach 2:
The inspection is performed after the separator is wound around the core, allowing detection of foreign objects that may have been trapped during the winding process. This timing ensures that any foreign objects introduced during slitting or winding are detected before the separator roll is used in battery production
3Measurement precision
If visible light and infrared light are used for surface inspection, then surface defects are detected, but defects inside the separator roll remain undetected
Solution Approach 1:
The patent changes the parameter of electromagnetic wave penetration capability by using electromagnetic waves that can pass through the separator roll material. This allows the inspection system to detect both surface defects and internal defects such as foreign objects trapped inside the wound roll, overcoming the limitation of light-based surface-only inspection methods
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
Enables efficient and accurate inspection of separator rolls for defects inside the roll, reducing production costs and preventing short circuits by allowing inspection post-winding with a single device.
Implementation Method 1
a radiation source section configured to emit an electromagnetic wave to a separator roll including (i) a core in a cylindrical shape and (ii) a separator for use in a battery which separator is wound around the core, the electromagnetic wave being capable of passing through the separator roll
Data Source
AI summary
To inspect a separator roll for a defect inside the separator roll with use of only a small number of defect inspection devices, a defect inspection device (1) includes: a radiation source section (2) configured to emit an electromagnetic wave (4) to a separator roll (10); and a sensor section (3) configured to detect the electromagnetic wave (4) having passed through the separator roll (10).