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非破壊検査｜リチウムイオン電池
近年、カーボンニュートラル実現に向けた環境への配慮を背景にHV/PHEV/BEVが急速に普及しており、リチウムイオン電池（LiB: Lithium-ion battery）の需要が高まっています。
その一方で、LiBは僅かな異物・欠陥が発熱・発火に繋がる恐れのある繊細な部品です。製品としての最終検査だけでなく、原材料の品質検査や製造過程での異物・欠陥検査を実施することで、LiBの安全性を向上する取り組みが行われています。
LiBの製造工程/代表的な検査
LiB に起因した発熱・発火事故の原因のほとんどは、LiBの正極と負極間のショート（短絡）によるものです。電極間がショートする原因はさまざまですが、ここでは、将来的にショートする可能性のあるLiBを選別するために製造工程で実施されている、シート材料検査と形成品検査での代表的な検査内容をご紹介します。
シート材料検査
LiBの電極に使用される電極材シートの製造工程では、電極シートや電極材料の異物検査のほか、金属シートやセパレータ・外装材のピンホール検査が行われています。
異物検査
ピンホール検査
成形品検査
巻回・積層電極の製造工程とLiB完成品の検査では、X線検査による電極間距離検査やシワ検査、溶接状態検査が行われています。LiBは電極などの構成部材や形状の違いによってさまざまな種類があります。種類ごとに最適な検査方法も異なってくるため、検査方法の選択はLiBの品質管理において非常に重要です。
LiBの種類と最適な検査方法
LiBの電池形状は、「円筒型」「角型」「パウチ型（ラミネート型）」の3種類が主流ですが、内部の電極構造（積層型または巻回型）によりX線による内部検査方法は異なります。インラインで検査するか、オフラインで検査するかによって使用するX線検出器も変わってきます。
以下に「円筒型」「角型」「パウチ型（ラミネート型）」のLiBにおける正極・負極間距離の代表的な検査方法及び使用されるX線源、検出器をご紹介します。
各LiBの代表的な検査方法
巻回型（円筒型）
ストップアンドゴーで、サンプルをひとつずつ検査します。サンプルの電極端部を撮像し、電池内部の正極・負極ギャップなどを確認します。より短いタクトタイムが求められる場合は、ラインを止めずノンストップで検査します。
積層型（パウチ型）
サンプルを回転させながら、ストップアンドゴーで、ひとつずつ検査を行います。サンプルの角を撮像し、積層のずれを確認します。より短いタクトタイムが求められる場合、ノンストップのラインを構成します。その際、センサを2つ設置し、2箇所の角を同時に撮像することも可能です。
巻回型（角型）
巻回された電極の不良を、ストップアンドゴーで検査します。サンプルの2箇所の角を撮像して、巻回ずれなどを確認します。
撮像例
部材（電極タブ・溶接部）
詳細な溶接具合を確認。
部材（電極タブ・溶接部）
微小金属異物を検出。
車載用円筒型LiB①
1分間で500個を超える速さで、正極・負極のギャップ検査。
車載用円筒型LiB②
正極・負極のギャップ検査。
車載用大型LiB（角型：積層）
車載用大型LiBにおける内部構造の検査。
車載用大型LiB（パウチ：積層）
スタックされた正極・負極のギャップ検査。
部材（アルミケース）
アルミケース溶接部のボイド（気泡）を確認。
インラインCT検査の実現に向けて
LiBの故障原因が徐々に明らかになっていく中で、より複雑な構造の検査や微細な欠陥を見つける要望が高まってきており、オフライン検査や抜き取り検査での3D画像が求められるようになってきました。将来的にはインラインでの全数検査で3D画像が求められると考えられています。
弊社は、高精細なX線CT画像を取得するために不可欠なマイクロフォーカスX線源、高速動作可能なX線フラットパネルセンサの両製品の開発・製造を行っている世界でも数少ない企業です。いずれ寄せられるであろうインラインCT検査のニーズに対するソリューションもご提案いたします。
装置構成例
撮像例
関連製品
その他の業界
試写のご案内
浜松ホトニクスは、試写を通じて非破壊検査における最適なソリューションを提案します。
浜松ホトニクスでは、お客様からの非破壊検査のご要望に対する事前評価として、各種X線源やセンサ、カメラによる試写を行っております。弊社は非破壊検査装置メーカーではないため、特定のメーカーの装置に偏らず最適な光源、検出器などの面からデバイス・装置の選定をお手伝いいたします。
また、最適なデバイスの紹介だけでなく、長年のビジネスで培った経験をもとに、撮影のコツやノウハウも含めた最適なソリューションを提案いたします。お気軽にお問い合わせください。
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