Battery Module Insertion Apparatus with Protective Film Transfer
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Solution Overview
Problem
The existing battery module manufacturing processes face challenges with high failure rates due to collisions and friction between the battery assembly and the module housing during insertion, leading to damage and inefficiencies in the manufacturing process.
Innovation Solution
A battery module manufacturing apparatus equipped with a protective film supply and transfer unit that covers and retrieves a protective film to minimize collisions and friction, using two protective film supply rolls to share the role of supplying and retrieving the film, and a heat dissipation pad with a continuously thickening structure to reduce friction and facilitate insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery assembly is inserted directly into the module housing without protective film, then the insertion process is simpler and faster, but the outer surface of the battery case and cooling member collide or friction with the side wall of the module housing causing damage
Solution Approach 1:
The protective film is supplied and positioned on the outer surface of the battery assembly before the insertion process begins. This preliminary protective action prevents collision and friction damage during insertion without requiring complex modifications to the insertion mechanism itself.
Solution Approach 2:
The protective film acts as an intermediary layer between the battery assembly (including cooling member) and the module housing side wall. This intermediary prevents direct contact and potential damage while allowing the insertion process to proceed.
2Productivity
If a single protective film supply roll is used, then the device structure is simpler, but the manufacturing time increases due to sequential supply and retrieval operations
Solution Approach 1:
The protective film supply system is segmented into two independent supply rolls working simultaneously - one for supplying the protective film and another for retrieving it. This parallel operation eliminates sequential waiting time and accelerates the manufacturing process.
Solution Approach 2:
The two protective film supply rolls operate continuously and simultaneously throughout the insertion process - one continuously supplying film while the other continuously retrieves it. This continuous parallel action maintains constant productivity without interruption.
3Reliability
If the protective film is not retrieved after insertion, then the process is simpler, but the damaged protective film remains in the module housing causing potential failures
Solution Approach 1:
The system implements both discarding and recovering functions for the protective film. The first supply roll discards the used protective film after insertion, while the second supply roll recovers and retrieves the film from the module housing, ensuring clean disposal and preventing contamination.
Solution Approach 2:
The second protective film supply roll acts as an intermediary retrieval mechanism that removes the damaged protective film from the module housing after insertion is complete, preventing potential failures while maintaining a clean final product.
Data Source
AI summary
Provided a battery module manufacturing apparatus configured to insert a battery assembly into a module housing. The battery module manufacturing apparatus, which inserts a battery assembly including a plurality of secondary batteries into a module housing, includes: a protective film supply unit configured to supply a protective film so as to cover an outer surface of the battery assembly or to retrieve the protective film from the outer surface of the battery assembly; and a protective film transfer unit configured to move in an insertion direction in which the battery assembly is inserted into the module housing and a direction opposite to the insertion direction in a state of holding a part of the supplied protective film.