US 12749723 B2 / Sep 29, 2026

Dynamic control and performance assessment/optimization of secondary battery cell finishing (formation/aging/sorting/grading) utilizing simultaneous inline electrochemical methods and closed-loop process control

Control, assessment and optimization techniques for manufacturing secondary electrochemical devices to improve the quality, throughput, and safety of cells produced and to facilitate the finishing (formation/aging/sorting/grading) process. A system for dynamic control and optimization of secondary battery finishing process includes a closed-loop process control module that is configured to process real-time in-line manufacturing data derived from at least one of electrochemical impedance spectroscopy (EIS), self-discharge analysis (SDA), amperometric, or potentiometric battery measurements. Cell formation can be reduced from the several days with prior art technology to less than 24 hours, and aging can be reduced from 2-3 weeks to less than an hour. A control module provides real-time feedback to predecessor operations/materials for confirmations, refinements, corrections, and/or recognition or isolation of better/worse performance characteristics. It also provides feedforward information of aspects recognized that may indicate performance deviations from the norm.