Vacuum Punch and Edge Roller Sealing for Battery Housing Die-Cuts
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Solution Overview
Problem
Existing methods for applying self-adhesive die-cut parts to vehicle components, particularly battery housings, face challenges such as unintentional detachment, insufficient pressure application, and complexity in hard-to-reach areas, leading to potential safety risks and inefficiencies.
Innovation Solution
A method and application unit utilizing a vacuum punch and a separate roller unit to independently apply and press self-adhesive die-cut parts onto vehicle components, ensuring secure adhesion and minimizing detachment risks, especially in complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a vacuum punch is used to apply self-adhesive die-cut parts, then the application speed and automation are improved, but the pressure application at the outer edges is insufficient causing detachment
Solution Approach 1:
The patent divides the application process into two independent stages: first the vacuum punch applies the die-cut part to the substrate, then the roller unit separately presses the outer edges. This segmentation allows each component to perform its specialized function optimally without compromise.
Solution Approach 2:
The roller unit acts as an intermediary element that bridges the gap between the vacuum punch application and the final secure adhesion. It provides the additional edge pressure needed to prevent detachment without interfering with the initial vacuum-based placement.
2Reliability
If manual application methods are used, then pressure can be applied to ensure adhesion, but the productivity and automation level are low
Solution Approach 1:
The patent merges the automated vacuum punch system with the pressure-application function of manual methods by integrating the roller unit. This combination achieves both high automation/productivity and reliable adhesion with proper edge pressure.
Solution Approach 2:
The roller unit is automatically actuated by the control system to provide edge pressure after vacuum punch application, eliminating the need for manual intervention while maintaining the adhesion reliability that manual methods provided.
3Reliability
If the roller unit presses the entire surface, then adhesion is improved, but the risk of damaging the stamped part or substrate increases
Solution Approach 1:
The roller unit is designed to apply pressure only at the outer edges of the die-cut part rather than across the entire surface. This localized pressure application secures the edges (where detachment most commonly occurs) while avoiding damage to the stamped part or substrate from excessive overall pressure.
4Adaptability or versatility
If label dispensers are used in hard-to-reach areas, then the application capability is improved, but the space requirements and robot movement precision demands increase
Solution Approach 1:
The roller unit is designed with movable components that can dynamically adjust their position and orientation to access die-cut parts in various locations, including hard-to-reach areas. This dynamic design reduces the need for large clearance spaces and complex robot movement sequences.
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
The method enables efficient, secure, and time-effective application of self-adhesive die-cut parts, even in hard-to-reach areas, reducing the risk of detachment and enhancing safety by ensuring proper adhesion, particularly for overpressure protection in battery housings.
Implementation Method 1
a vacuum punch (6), in which a vacuum is activated, is provided
Implementation Method 2
a roller unit (61), which is guided to the stamped part after stamping and is moved in such a way that it follows the outer edge of the contour of the stamped part and thus presses the stamped part onto the vehicle element
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The invention relates to a method for the automated application of a self-adhesive die-cut part (7) to a vehicle component (1), such as a battery housing, by means of an application unit (100) attached to a robot arm, wherein a self-adhesive die-cut part (7) is detached from a die-cut strip (8) having a longitudinal direction (L) by means of a cylinder (5) having an effective axis (W) and comprising a vacuum punch (6), and is then stamped onto a vehicle component (1), wherein the die-cut strip (8) is provided, the vacuum punch (6) is moved into a transfer position, a vacuum is activated in the vacuum punch (6) in the transfer position, the self-adhesive die-cut part (7) is fixed to the vacuum punch (6) by moving the vacuum punch in the direction of the self-adhesive die-cut part (7) by means of the vacuum, and the self-adhesive die-cut part (7) is detached from the die-cut strip (8).by moving the vacuum punch (6) at least far enough away that the self-adhesive die-cut part (7) is completely detached from the die-cut strip (8), and - the vacuum punch (6) is moved into a position over the vehicle element (1) and the self-adhesive die-cut part (7) is applied to the vehicle element (1) by moving the vacuum punch (6) by the cylinder (5) from the transfer position along the effective axis (W) into an application position in which the self-adhesive die-cut part (7) is stamped onto the vehicle element (1), - the vacuum punch (6) is moved away after stamping, wherein a separate roller unit (61) comprising at least one roller (62, 63) is provided which is guided to the die-cut part after stamping and moved such that the at least one roller (62, 63) traces the outer edge of the contour of the die-cut part (7) and thus presses the die-cut part onto the vehicle element (1).