Battery Pack TIM Transfer Using a Release Sheet
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for installing thermal interface material (TIM) in traction battery packs are inefficient, contributing to prolonged assembly cycle times due to direct application on components, which can be time-consuming and not amenable to automation.
Innovation Solution
Dispensing TIM onto a release sheet, applying it to a component, and then separating the release sheet while the TIM remains bonded to the component, allowing for automated transfer and compression, thereby reducing cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermal interface material is applied directly to battery components, then bonding accuracy is improved, but assembly cycle time increases
Solution Approach 1:
The TIM is dispensed onto a release sheet in advance before the actual assembly operation. This preliminary placement allows the TIM to be ready for transfer to the battery component, eliminating the need for direct application during assembly and thereby reducing cycle time while maintaining bonding accuracy
Solution Approach 2:
A release sheet is introduced as an intermediary carrier between the TIM dispensing system and the battery component. The TIM is first applied to the release sheet, which then serves as a temporary holding surface that facilitates easy transfer to the final component without direct application, thus improving both efficiency and precision
2Reliability
If manual TIM application is used, then bonding quality is maintained, but automation capability is reduced
Solution Approach 1:
The release sheet acts as an intermediary that enables automated handling of the TIM. By placing the TIM on the release sheet first, automated systems can pick up the entire release sheet with TIM attached and transfer it to the battery component, achieving both automation and consistent bonding quality
Solution Approach 2:
The manual direct application process is replaced by an automated transfer mechanism using the release sheet. The release sheet allows robotic or automated systems to handle and position the TIM accurately without requiring manual dexterity, thus enabling automation while maintaining bonding reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances assembly efficiency by automating the TIM application process, reducing overall cycle times and facilitating consistent bonding of TIM to battery pack components.
Implementation Method 1
separating the release sheet from the thermal interface material while the thermal interface material remains on the component of the traction battery pack
Implementation Method 2
transporting the thermal interface material on the release sheet using a conveyer assembly to a position closer to the component
Implementation Method 3
compressing the thermal interface material against the component during the applying of the thermal interface material to the component
Implementation Method 4
heating the release sheet to heat the thermal interface material
Data Source
AI summary
A method of assembling components of a traction battery includes dispensing a thermal interface material onto a release sheet. While the thermal interface material remains on the release sheet, the method applies the thermal interface material to a component of a traction battery pack. The method then separates the release sheet from the thermal interface material while the thermal interface material remains on the component of the traction battery pack.