Staged Helium Injection for Sealed Battery Leak Detection

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Solution Overview

Problem

In sealed battery manufacturing, the introduction of detection gases like helium often results in leakage and poor welding due to fast airflow causing electrolyte to be blown off and vaporized during the sealing process, leading to suboptimal sealing performance.

Innovation Solution

A method where the detection gas is introduced by starting at a lower pressure and gradually increasing it to the predetermined pressure in stages, using a supply nozzle and proportional flow valve to control the injection pressure, reducing the flow speed and preventing electrolyte attachment to the outer surface of the battery container.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If helium is introduced at high pressure to reduce leakage, then detection gas leakage is reduced, but electrolyte is blown off and vaporized causing poor welding

Engineering Contradiction:
Improvedetection gas leakage preventionVSAvoidwelding quality
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies dynamics by transitioning from static high-pressure injection to dynamic staged pressure injection. The injection pressure is dynamically adjusted in multiple stages (first stage: low pressure, second stage: high pressure) based on the timing of the process, allowing the system to adapt to different requirements at different times - reducing leakage when needed while preventing electrolyte blowoff during critical welding phases

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements periodic action through staged pressure injection cycles. The helium injection is divided into periodic stages with distinct pressure levels - a first injection period at low pressure followed by a second injection period at high pressure. This periodic variation in injection pressure allows the system to achieve both leakage prevention and welding quality protection by applying appropriate pressure at appropriate times

Inventive Principle:
Principle #19Periodic action

2Volume of moving object

If helium injection pressure is increased to reach distant positions, then detection coverage is improved, but flow speed becomes too fast causing electrolyte attachment to outer surface

Engineering Contradiction:
Improvedetection gas coverage volumeVSAvoidelectrolyte attachment to outer surface
Core Design Contradiction:
Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent applies segmentation by dividing the single high-pressure injection process into multiple staged injection periods. The first stage uses low pressure to prevent harmful electrolyte attachment, while the second stage uses high pressure to achieve sufficient detection coverage. This segmentation of the injection process into distinct pressure stages allows simultaneous achievement of both coverage and harm prevention

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent implements preliminary action by performing low-pressure helium injection before high-pressure injection. The first staged injection at low pressure prepares the system by preventing electrolyte attachment to the outer surface, creating favorable conditions for the subsequent high-pressure injection that achieves detection coverage without the harmful side effects

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

This approach reduces gas leakage and prevents poor welding by maintaining a stable flow speed and minimizing electrolyte attachment, ensuring better sealing quality and reducing manufacturing costs.

Implementation Method 1

introduction of a detection gas into the battery container in such a manner that injection of the detection gas from the supply nozzle is started at a pressure smaller than a predetermined injection pressure, and then an injection pressure of the detection gas is increased by stages

Methodology Applied
Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentUS10158147B2Sealed battery manufacturing method
Publication Date: 2018.12.18 TOYOTA JIDOSHA KK
  • US10158147B2 patent drawing
  • US10158147B2 patent drawing
  • US10158147B2 patent drawing

AI summary

A sealed battery manufacturing method includes inserting a supply nozzle (120) into an opening (33) that is opened outwardly, the opening (33) being formed in a battery container (33); and introducing a detection gas (He) into the battery container in such a manner that injection of the detection gas from the supply nozzle (120) is started at a pressure smaller than a predetermined injection pressure, and then an injection pressure of the detection gas (He) is increased by stages until the injection pressure of the detection gas (He) reaches the predetermined injection pressure.