Vented Stencil Printing for Bubble-Free Adhesive Seals
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Solution Overview
Problem
The risk of air bubbles forming during template printing of sealants and adhesives in electrochemical cells increases with thicker templates, leading to incomplete prints and defects due to the increased volume of recesses to be filled, which is a challenge in achieving higher layer heights required for seals in these cells.
Innovation Solution
Incorporating channels into the stencil to vent air out during the filling process, allowing the recess to be completely filled without air bubbles by positioning the channels to receive excess adhesive and ensuring the doctor blade direction aligns with the venting channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If thicker templates are used to achieve higher layer heights (up to 1500 μm) for seals in electrochemical cells, then the layer thickness requirement is met, but the risk of air bubbles forming during the doctor blade process increases
Solution Approach 1:
The template is segmented by introducing channels that divide the recess volume into vented regions. These channels create multiple smaller cavities or pathways that allow air to escape progressively as the recess is filled, preventing large trapped air volumes that cause defects.
Solution Approach 2:
The channels act as intermediary pathways between the recess interior and the exterior environment. They provide a controlled medium through which air can be evacuated during the filling process, mediating between the incoming sealant/adhesive and the air already present in the recess.
2Adaptability or versatility
If thicker templates are used to compensate for tolerances and enable complex seal structures, then design freedom and tolerance compensation are improved, but the volume of recesses to be filled increases leading to more air bubbles
Solution Approach 1:
By segmenting the recess through channel integration, the patent enables thicker templates with complex geometries to be filled reliably. The channels break down the large recess volume into manageable sections that can be filled sequentially with air escape paths, making thick templates suitable for complex seal designs.
Solution Approach 2:
The channels add a new dimensional aspect to the recess structure by creating vertical or lateral pathways through the template thickness. This dimensional addition provides air escape routes that were not available in flat, two-dimensional filling processes, enabling reliable filling of thick three-dimensional recesses.
3Volume of stationary object
If the recess volume is increased to achieve higher layer heights, then the required seal thickness is obtained, but the air bubble formation risk increases due to larger recess volume
Solution Approach 1:
The large recess volume is segmented by channels into smaller sub-volumes or filling zones. This segmentation allows the filling process to proceed in stages with air being evacuated through channels as each zone is filled, preventing the formation of large trapped air bubbles that would cause printing defects.
Solution Approach 2:
The channels enable the extraction of air from the recess during the filling process. By providing dedicated pathways for air removal, the channels separate the air evacuation function from the sealant filling process, allowing the recess to be completely filled without air bubble entrapment.
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
Minimizes the risk of air bubbles, enabling the use of thicker stencils for higher layer thicknesses up to 1500 μm, ensuring defect-free printing of seals in electrochemical cells.
Implementation Method 1
The at least one channel integrated into the stencil allows venting of the recess when filling with the sealant and/or adhesive so that the risk of an air bubble remaining in the recess decreases
Data Source
AI summary
The invention relates to a device for printing a substrate (1) with a sealant and/or adhesive (2), comprising a stencil (3) with an upper side (3.1) and a lower side (3.2) and at least one recess (4) extending from the upper side (3.1) to the lower side (3.2) for receiving the sealant and/or adhesive (2), wherein at least one channel (5) connected to the recess (4) is integrated into the stencil (3).The invention also relates to a method for printing a substrate (1) with a sealant and/or adhesive (2) using a device according to the invention.