3D Insulating Sheet Laser Cutting for EV Battery Trays
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing insulating sheets for electric vehicle battery trays are limited in producing three-dimensional shapes without press molds, leading to imprecise cutting and potential burrs.
Innovation Solution
A method involving forming grooves on a flat sheet, using laser cutting to precision-cut the grooves into three-dimensional shapes, attaching tape for secure fixation, and bending the edges to fit the tray, all without the need for press molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mold processing is used for forming and cutting insulating sheets, then flat shapes can be manufactured efficiently, but three-dimensional shapes cannot be manufactured precisely
Solution Approach 1:
The patent replaces the mechanical press mold system with a laser beam system. The laser beam irradiates the insulating sheet to cut both flat surfaces and side surfaces, enabling precise three-dimensional shaping without mechanical contact. This substitution allows the system to handle complex 3D geometries that were impossible with traditional press molds while maintaining high cutting precision.
Solution Approach 2:
The patent transitions from two-dimensional flat cutting to three-dimensional shape formation by adding vertical cutting capability. The laser beam can irradiate not only the top surface but also the side surfaces of grooves, creating true 3D structures. This dimensional expansion allows manufacturing of insulating sheets that fit complex battery tray geometries with precise three-dimensional shapes.
2Ease of manufacture
If mechanical cutting is used to cut insulating sheets, then cutting can be performed with preset patterns, but burrs are generated on the cut surface
Solution Approach 1:
The patent replaces mechanical blade cutting with laser beam cutting. The laser beam vaporizes or melts the material along the cut path, eliminating mechanical contact that causes burrs. This non-contact cutting method produces clean cut surfaces without the burrs and surface damage associated with mechanical blades, while maintaining efficient cutting speeds through automated laser scanning.
3Device complexity
If press molds are used for forming insulating sheets, then manufacturing can be performed with simple equipment, but three-dimensional shapes cannot be formed
Solution Approach 1:
The patent replaces complex mechanical press molds with a laser beam system that can form three-dimensional shapes through selective material removal. The laser system uses computer-controlled movement to irradiate specific areas, creating grooves and contours that define the 3D shape. This approach eliminates the need for complex mold assemblies while achieving high precision in three-dimensional form accuracy.
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 enables precise cutting of complex three-dimensional shapes, improves production yield, and ensures secure fixation of the insulating sheets to the battery tray, preventing electrical malfunctions and fires.
Implementation Method 1
a first cutting step for cutting a side surface of the groove by irradiating a laser beam to a side surface of the sheet
Implementation Method 2
a second cutting step for cutting the insulating sheet to completely separate the groove from the insulating sheet by irradiating a laser beam from above the groove having the side surface cut
Implementation Method 3
a jig unit that fixes the insulating sheet in an pneumatic suctioning manner in the tape attaching step
Data Source
AI summary
Disclosed is a method of manufacturing an insulating sheet, comprising: forming at least a groove on a flat sheet; a first cutting step for cutting a side surface of the groove by irradiating a laser beam to a side surface of the sheet; a second cutting step for cutting the insulating sheet to completely separate the groove from the insulating sheet by irradiating a laser beam from above the groove having the side surface cut; a tape attaching step for attaching a tape to an outer surface of the insulating sheet; and a bending step for bending one end portion of the surface of the insulating sheet having the tape attached toward a place where the tape is attached. It is possible to mass-produce the insulating sheets having a three-dimensional shape, regarded as being difficult to manufacture with a mold.