Li-Ion Batteries

Copper and Aluminum Foil  – Quality Challenges

• Copper and aluminum foils must be defect-free. Bumps, dents and pinholes should not be processed into batteries.
• Manual inspection is time consuming, expensive, subjective and inexact; critical defects cannot be reliably detected, manually.
• Conventional camera technologies do not deliver consistent bump/dent/scratch detection. The reflective nature of the foils cause these systems to miss defects and generate false hits. These systems require constant tuning and checking.

Dark Field Solution

• Solid State Laser Reflection (SSLR) scanners deliver the highest resolution in the industry (1μm); darkfield and brightfield scanner designs.
• Special technology for reflective foils delivers extraordinary defect detection of all critical defects.
• SSLR scanners solve all the problems associated with conventional camera and laser systems. Systems are self-aligning. No more false hits or missed defects due to misalignment of the camera and light source.

Slot Die and Patch Coatings – Thickness Measurement Challenges

• On-line, real-time measurements required.
• Wet coating and post-dryer.
• Installation space often very tight.
• Precise point measurements required, not large area measurements.

Dark Field Solution

• Laser scanner(s) traverse the web.
• Wet and dry coating measurements.
• Very compact scanner – traversing scanner and support structure is only 4” wide (machine direction measurement).
• High precision coating profile: 1,000 measurements per second.

Scratch Detection Challenges

• On-line Scratch and Sleek detection can be extremely difficult.
• Many systems cannot detect subtle scratches and sleeks.
• Scratches/Sleeks in the machine-direction (or conveyor direction) are the most common and the most difficult to detect.

Special Scratch/Sleek Detection

• Special optics detect subtle scratches and sleeks.
• Special  processing/software module improves scratch measurement.

Turnkey Inspection Systems – Customer Needs

• Existing production line: Integration of the inspection system with the existing customer production line.
• Complete turnkey system – Stand alone: Stand-alone system – off-line and development, including roll unwind, rewind, sheet handling.

Dark Field Capabilities

• Existing production line: Dark Field provides complete interface and integration services.  This means mounting the system to the machine frame or the floor.  Customers only need to provide mounting holes or anchor bolts and power.  Dark Field does the rest, including I/O and data interfaces.
• Complete turnkey system – Stand alone: Custom solutions.  Systems are full production systems and can be easily modified/upgraded for relocation to the production line.