Assembling Battery Machines TRIZ Cases

Two-stage pouch sealing creates a folding line and deformed region that protect the insulating resin layer while preserving cell sealing integrity.

Built-in cooling vanes route coolant through the cell fixture, cutting separate parts and easing battery module assembly while limiting overheating.

Ultrasonic bonding joins battery separator roll ends without tape, improving bond uniformity while automating protective film removal.

A movable finishing unit tracks the semi-finished cell during transport, preserving finishing precision without slowing battery cell production.

Oblique air jets and timed suction clear foreign matter from electrode tab-lead compression zones without weakening the joint.

A grooved insulating member nests a flanging portion to keep end cap insulation reliable while reducing cell size and improving energy density.

Automatic bobbin changeover and vacuum-assisted separator end splicing keep battery electrode film supply running with less downtime and safer handling.

Dual-table separator feeding and electrode positioning improve stacking speed while maintaining alignment accuracy and reducing defects.

Virtual degas training with adjustable parameters and quality feedback helps battery workers handle defects without disrupting production.

Zero-relative-speed foil release and constant strip tension enable faster battery electrode stacking with precise alignment and less sail-effect damage.

Dual tables, separator reels, and motorized positioning speed electrode stacking while keeping cathodes and anodes accurately aligned.

Maintaining a 0-30 mm gap during separator strip stacking reduces sail-effect damage and preserves precision at higher battery cell production speeds.

Maintaining a constant separator-strip angle during stacking reduces sail-effect deformation and tension, enabling faster battery cell assembly.

A switchable vacuum and compressed-air dispenser removes battery product segments in line for calibration, splice rejection, and flexible routing.

A roller squeezes and rotates the battery cell rolled edge to improve sealing, uniform deformation, and pressure resistance.

Dot-shaped separator adhesion with central non-adhesive regions limits wrinkles and winding deviation during flat wound electrode pressing.

Pre-winding two separators on the winding core cuts battery winding tact time while keeping electrode alignment stable and reducing stacking displacement.

Dot-pattern separator adhesion with central non-adhesive regions improves winding alignment and reduces wrinkles during battery pressing.

Opposing variable-speed rollers compensate intermittent support motion to cut and convey strips cleanly in high-speed battery winding.

A tilted sensor-lens setup lets one camera focus on positive and negative electrode planes at once, reducing vibration-driven misalignment.

Alternating gripperless transport feeds anodes and cathodes into a chamber for aligned pressing, boosting electrode stack throughput.

Preforming an annular groove before shell necking limits deformation, protects the electrode assembly, and reduces battery short-circuit risk.

Continuous end plates join adjacent battery stacks to improve mounting efficiency, case strength, heat dissipation, and usable inner space.

Vision feedback corrects cylindrical cell positions before busbar bonding, raising throughput and accuracy across different module sizes.

Digital twin simulation predicts actual process values from setpoints to improve battery cell quality, cost, and environmental control.

Image-based alignment corrects electrode assembly position before secondary sealing, keeping pouch battery gaps consistent and electrical characteristics stable.

Pre-formed electrode notches contain laser-cleaning burrs to prevent separator shorts while preserving cell thickness and energy density.

Precise weighing, quantitative feeding, and twin-screw kneading stabilize electrode mixing ratios and dispersion for consistent battery quality.

Heating blades locally heat and compress the pouch wing sealing part during bending to prevent microcracks and improve insulation resistance.

Interlocked end plates across adjacent cell stacks improve mounting efficiency, case rigidity, and thermal expansion tolerance.

Parallel sealed lines create controlled bend zones in pouch-cell edges, reducing volume while maintaining airtight sealing and leak resistance.

A hinged pressing jig holds bus bars and electrode leads in close contact for welding, removing lead bending and improving bond strength.

Integrated fixing brackets and housing secure and align cell stacks while cutting redundant parts, pack weight, and assembly steps.

A pressurizing jig compresses bus bars from the highest terminal position to close terminal gaps and prevent welding failures in battery packs.

Pressure sensors on the sealing surface detect local load deviation, helping pouch cell sealing stay uniform and reduce venting risk.

Rotating clamping assemblies align insulation film on bare cells to keep edge distances consistent and reduce short-circuit risk.

A two-stage arc-guided lead tab bending approach reduces spring back, avoids equipment collision, and improves compact cell assembly.

Localized protrusions and a reinforcing member reshape the battery cell crimping structure for more uniform sealing and safer production.

Using gravity and carriage motion, a locking block and rod achieve accurate battery line positioning without complex controls or costly mechanisms.

An integrated spacer and restraint member holds battery cells in position during processing, reducing displacement and tip-over.

A deformable foamed-resin separator improves cell heat insulation while managing thickness tolerance and restraint load variation.

A curved housing wall and flexible guide-rail unit reduce tearing from voltage peaks while absorbing shocks in battery pack interfaces.

A correction sheet and stepped pressing surface flatten electrode assembly height differences and bond non-bonded interfaces to reduce resistance.

An integrated vision section tracks electrode position inside the heating zone, catching temperature-driven misalignment without opening the unit.

Internal pressure transfer between battery-processing cavities cuts repeated air replenishment, reducing energy use while maintaining pressure.

Gas expands the assembled battery case before electrolyte injection, increasing fill volume and reducing repeated liquid injection steps.

A flame-retardant filler between cells and busbars redirects thermal runaway gas along a controlled path while improving module stability.

Cell widths are measured under compression, then compensating elements are placed between cells to keep battery modules at a defined overall width.

Coupled accommodation and sealing jigs apply uniform pressure to pouch batteries, preventing seal venting from internal gas.

Horizontal sealing units in one process chamber thermally fuse multiple battery cells at once, improving seal reliability and throughput.