Battery Module Tape Geometry for Clean Adhesive Cutting
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Solution Overview
Problem
Existing manufacturing processes for battery modules face issues with adhesive sagging and scattering during application, leading to welding defects and unclear replacement criteria for adhesive tape, resulting in waste and inefficiency.
Innovation Solution
A tape design with concave and convex portions on the adhesive surface, combined with optical sensors to guide timely replacement, ensures precise cutting and accurate adhesive application, minimizing waste and defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If adhesive is applied continuously during manufacturing, then productivity is improved, but adhesive sagging and scattering occur leading to manufacturing precision degradation
Solution Approach 1:
The adhesive layer is segmented into multiple discrete adhesive pieces along the length of the tape. This segmentation prevents the adhesive from sagging and scattering while maintaining continuous application capability, thus resolving the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The adhesive pieces are pre-formed and positioned on the tape before application. This preliminary action ensures that the adhesive maintains its shape and position during transport and application, preventing sagging and scattering while enabling continuous manufacturing.
2Device complexity
If adhesive tape is used without replacement guidance, then device complexity is reduced, but loss of information occurs regarding replacement timing leading to waste
Solution Approach 1:
A visual indicator (such as a colored mark or pattern) is incorporated into the adhesive tape to signal replacement timing. This allows operators to identify when tape replacement is needed without complex sensing systems, balancing device complexity with material utilization efficiency.
3Manufacturing precision
If adhesive is cut during gripper ascent, then manufacturing precision is improved, but adhesive scattering occurs causing harmful factors
Solution Approach 1:
The adhesive is divided into discrete pieces that are pre-separated along the tape. When cutting occurs during gripper ascent, these segmented adhesive pieces remain contained and do not scatter, thus maintaining manufacturing precision while eliminating the harmful scattering effect.
Solution Approach 2:
A release paper or carrier tape serves as an intermediary that holds the adhesive pieces in place during handling and cutting. This intermediary prevents direct contact and scattering of adhesive while allowing precise cutting and controlled application.
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A manufacturing method of a battery module including a step of attaching an adhesive to a battery cell includes a tape supply step in which a laminated tape having a release paper placed on one side and a sheet-like adhesive placed on the other side is continuously supplied to pass through a roller, and is supplied so that the release paper contacts the roller; an adhesive step in which a gripper gripping the battery cell glides over the roller so that the adhesive comes into contact with one surface of the battery cell, and thus the adhesive is separated from the release paper and adhered to the battery cell; and a cutting step in which the adhesive is cut by the ascent of the gripper, wherein the adhesive has a concave portion with a concave shape formed on the contact surface with the release paper so that the thickness is reduced compared to other places.