Solutions for Controlling Production Costs of Lithium-ion Batteries: Laser Displacement Sensors for Measuring Electrode Thickness

As the emphasis on and demand for renewable energy continue to rise, lithium-ion batteries have become a primary technology for applications such as electric vehicles, mobile devices, and energy storage systems. However, the performance and efficiency of lithium-ion batteries are influenced by various factors, among which the number of electrode layers is significant.

Electrodes are key components of lithium-ion batteries, responsible for storing and releasing charge. In lithium-ion batteries, the number of electrode layers indicates the layers between the positive and negative electrodes. Generally, a higher number of electrode layers leads to increased battery capacity and longer maintenance time, as well as higher voltage and power. However, in practical applications, increasing the number of layers does not always represent the best strategy for improving battery performance.

Once the raw materials for lithium batteries have passed inspection, they enter the coating process. The uniformity and edge distance of the slurry application undergo rigorous testing. After drying, the aluminum foil substrate for the positive electrode is coated on both sides and then enters the "cell assembly" stage, where the lithium polymer-coated substrate is cut into small pieces according to the size of the battery. These small pieces, consisting of positive and negative electrodes, are wrapped together with insulating materials, and after welding the tabs and completing the aluminum-plastic packaging, they undergo X-ray inspection for quality assurance. If any abnormal layering occurs, the battery may experience swelling or short-circuiting during later use. Finally, after a high-temperature bake to remove moisture, the electrolyte is injected, and the internal dryness of the battery determines its quality, resulting in the completion of the finished battery cell.

The coating thickness of electrodes directly relates to the battery's power generation efficiency and effective cost control. Below, we explain how DADISICK laser displacement sensors can measure the thickness of battery electrodes.

Additionally, since laser displacement sensors typically do not output direct distance values but rather analog signals proportional to the distance, a PLC (Programmable Logic Controller) is needed to read the output signals from the sensors. Through corresponding calibration and calculations, the signals are converted into actual distance values, enabling thickness measurement.

✅ Non-Contact Measurement: Does not cause any physical damage to the measurement object.