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
Engineering 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
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
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
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
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
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
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
Data Source
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.


