X-Ray Inspection of Batteries for Optimized Internal Design

Thousands of different applications use and rely upon batteries. Ranging from a firefighter’s flashlight, to a mobile device, to a defibrillator, battery testing and failure analysis is vital for improving the design and confirming the correct function of internal features.

With digital radiography and computed tomography X-ray inspection, the internal electrode arrangement can be examined after assembly and checked for any defects. X-ray inspection helps to understand the layout of the anode and cathode, and accurately measure internal linear distances and alignments, and quality of short circuits, electrical contacts, and misaligned components and much more.

Battery X-ray Inspection

Lithium sheets or lead sheets are rolled together to form a battery known as a jelly roll. Computed tomography (CT) enables users to see whether it is twisted, whether there is any nicked material, and determine the correct length and fitment.

Inspection can help to identify misplaced internals, and signs of holes and or voices in the stacked layers. The 4D technology demonstrated in the video below enables users to observe what happens to the battery when it is in a depleted state vs. a non-depleted state. Jelly-roll concentricity, alignment, and telescoping can also be inspected.

Lithium batteries possess high energy and can generate heat. Batteries are encased in stainless steel to prevent leakage or any potential harm. With CT, the welding used to cover the battery can be observed to ensure that the wall has the required thickness and is not too thin. The wall could break easily if it is very thin, and cause harm.

CT enables accurate measurements of internal linear distances and alignments and quality of short circuits, electrical contacts, and misaligned components.

With CT, 100% battery inspection is achievable. A complete inspection can be carried out in seconds per part with an automatic pass/fail signal output. To obtain more detailed data, factory QC, SCADA, or SPC systems can be linked. Batch or laboratory R&D versions are also available.

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This information has been sourced, reviewed and adapted from materials provided by North Star Imaging, Inc.

For more information on this source, please visit North Star Imaging, Inc.

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