Vacuum Punch and Roller Sealing for Battery Housing Die-Cuts
Find Innovative SolutionsGenerate Solutions
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 using a cylinder with a vacuum punch and a roller unit to securely apply self-adhesive die-cut parts, ensuring adequate pressure and preventing detachment by tracing the part's contour with rollers, allowing for efficient application even in complex vehicle geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual application of stamped parts is used, then flexibility and adaptability are maintained, but productivity is low and labor intensity is high
Solution Approach 1:
The robot arm performs the complete application process autonomously - picking up stamped parts from the strip, positioning them over openings, and applying pressure through the vacuum stamp mechanism. The system serves itself by integrating all necessary functions into one automated unit, eliminating manual intervention while maintaining high productivity.
Solution Approach 2:
The application unit combines multiple functions into a single device: the robot arm provides positioning and movement, the vacuum stamp provides both adhesion and pressing force, and the integrated mechanism handles both small and large stamped parts. This multi-functional design achieves high productivity without proportionally increasing system complexity.
2Productivity
If robot arm with vacuum stamp is used for automated application, then productivity increases, but reliability decreases due to insufficient pressure application
Solution Approach 1:
The vacuum stamp mechanism merges two functions into one component: the vacuum suction provides both the gripping force to hold the stamped part during transfer and the pressing force to ensure reliable adhesion during application. This combination eliminates the need for separate pressing mechanisms and ensures consistent pressure application, improving reliability while maintaining high productivity.
Solution Approach 2:
The system dynamically adjusts the vacuum pressure parameter to achieve optimal adhesion. By controlling the vacuum level, the system ensures sufficient pressing force for reliable bonding while maintaining the ability to release and reposition parts if needed. This parameter control ensures consistent adhesion quality across all applications.
3Extent of automation
If label dispenser mounted on robot arm is used, then automated application is achieved, but device complexity and space requirements increase
Solution Approach 1:
The invention extracts the essential function of the label dispenser - the vacuum gripping and pressing mechanism - and integrates it directly into the robot arm's end effector. This eliminates the need for a separate, space-consuming label dispenser unit while maintaining full automation. The vacuum stamp mechanism is positioned exactly where needed, reducing overall system complexity and space requirements.
4Productivity
If conventional vacuum stamp method is used, then automated application is achieved, but detachment occurs due to insufficient edge pressure
Solution Approach 1:
The vacuum stamp mechanism applies localized pressure exactly where needed - at the edges and contact points of the stamped part. The vacuum suction creates distributed pressure across the entire adhesive surface, with enhanced pressure at critical edge areas. This local quality of pressure distribution prevents detachment while maintaining overall bonding strength, ensuring reliable adhesion throughout the application process.
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 ensures reliable adhesion of die-cut parts, reduces detachment risks, and allows for faster, more precise application in hard-to-reach areas, enhancing safety and efficiency in sealing vehicle components like battery housings.
Implementation Method 1
in the transfer position a vacuum is activated in the vacuum punch and the self-adhesive die-cut part is fixed to the vacuum punch by the vacuum
Data Source
Figure 1
Figure 2
Figure 3
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 by moving the vacuum punch (6) into a position above the vehicle element (1) and applying the self-adhesive die-cut part (7) 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), wherein a roller unit (61) comprising at least one roller (62, 63) is provided in the vacuum punch (6), wherein the vacuum punch (6) is moved after stamping 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).