Thermal Unit Cell Edge Inspection for Electrode Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing electrode assemblies in secondary batteries face challenges in accurately measuring the position of negative electrodes within unit cells, leading to significant deviations in full length and full width between cells, which can result in placement failures.
Innovation Solution
A unit cell inspecting device utilizing long-wave infrared rays to capture thermal images of electrode edges, measure their positions, and inspect for deformities, enabling precise alignment and placement of unit cells based on the negative electrode positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measurement methods are used to measure electrode positions in unit cells, then the measurement process is simple, but the measurement precision is insufficient leading to significant deviations in full length and full width between cells
Solution Approach 1:
The patent replaces conventional mechanical or optical measurement systems with a thermal imaging-based measurement system. The inspection device uses a heating unit to thermally excite the electrode and a thermal imaging camera to detect the thermal radiation pattern, thereby determining electrode positions and edges without physical contact. This substitution enables precise measurement of electrode positions (resolving the measurement precision issue) while maintaining a relatively simple device structure (heating unit + thermal camera + processor).
Solution Approach 2:
The patent changes the measurement parameter from visual/optical properties to thermal properties. By heating the electrode and detecting its thermal radiation signature in the infrared spectrum, the system can accurately identify electrode edges and positions based on thermal patterns rather than visual appearance. This parameter change allows precise measurement even when electrodes are obscured or have similar visual characteristics to surrounding materials.
2Manufacturing precision
If unit cells are disposed in multiple stages on the basis of the positive electrode, then the positive electrode area is smaller making alignment easier, but the negative electrode area is larger causing significant deviation in full length and full width
Solution Approach 1:
The patent replaces manual or mechanical alignment methods with an automated thermal imaging-based measurement and alignment system. The inspection device automatically captures thermal images, processes the images to identify electrode edges and positions, and provides alignment data for stacking operations. This automation resolves the conflict by achieving high alignment precision through accurate thermal measurement while reducing operational complexity through automated image processing and alignment calculation.
Solution Approach 2:
The patent creates a thermal copy (thermal image) of the electrode structure that can be analyzed and measured without physically manipulating the actual electrodes. By working with the thermal image copy, the system can precisely determine electrode positions and dimensions, and generate alignment information, without the difficulties of direct physical alignment operations on the actual battery components.
3Measurement precision
If the negative electrode is located inside the unit cell between separators, then accurate measurement is difficult due to obstruction, but long-wave infrared rays can pass through the separator to capture the thermal image
Solution Approach 1:
The patent uses thermal radiation as an intermediary to detect the electrode. The heating unit generates thermal energy that propagates through the separator (acting as a medium) to reach the electrode, and the thermal imaging camera detects the thermal radiation returning from the electrode through the separator. This intermediary approach allows measurement of the internal electrode without direct line of sight, resolving both the measurement precision requirement and the detection difficulty caused by the separator obstruction.
Solution Approach 2:
The patent changes the detection parameter from visual/optical transparency to thermal radiation transmission. Since long-wave infrared radiation can pass through the separator material that obstructs visual detection, the system detects electrodes by their thermal signature rather than visual appearance. This parameter change enables precise measurement of internal electrodes located between separators, as the thermal imaging camera can see through the separator to the heated electrode.
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 solution significantly reduces deviations in the full length and full width between unit cells, preventing placement failures and ensuring accurate assembly of electrode assemblies by accurately measuring and aligning negative electrodes using long-wave infrared technology.
Implementation Method 1
a main heating part configured to heat the edge of the unit cell, thereby raising a temperature of the edge of the electrode provided in the unit cell
Implementation Method 2
an image capturing part configured to capture the image of the edge of the unit cell by using the long-wave infrared rays, thereby acquiring a thermal image of the edge of the electrode provided in the unit cell
Data Source
AI summary
A unit cell inspecting device includes an inspection unit which captures an image of an edge of a unit cell using long-wave infrared rays and measures a position of an edge of an electrode provided in the unit cell. The inspection unit includes: a main heating part configured to heat the edge of the unit cell, thereby raising a temperature of the edge of the electrode provided in the unit cell; and an image capturing part configured to capture the image of the edge of the unit cell by using the long-wave infrared rays, thereby acquiring a thermal image of the edge of the electrode provided in the unit cell; and an inspection part configured to measure the edge of the electrode in the thermal image captured by the image capturing part, thereby measuring the position of the electrode by using the measured edge of the electrode.