One single battery cell will not get the wheels of an electric vehicle (EV) moving. Therefore, multiple battery cells are combined or stacked in a module capable of powering the vehicle. Battery cells also come in different shapes and forms and are delicate and sensitive to heat and force. It can be a challenge to find the best dispensing solution that delivers a result that meets stipulated safety, elasticity, and longevity requirements throughout the lifetime of the battery.
Stacking battery cells into modules is a short-cycle precise process with the utmost quality demands. Defects are not accepted, and there are no second chances to get it right. The battery cells need to be firmly attached, and the joint must meet the highest requirements in terms of rigidity and crash behavior. Full contact and insulation properties must be achieved, and pockets of air avoided. In the case of a crash, air pockets can lead to short circuits, a major safety issue in high-voltage EV power systems.
Challenges with different forms of battery cells
As if these requirements do not represent a challenge, the joint also needs to be elastic, providing a tolerance for the cells to expand slightly when charging and discharging. And finally, the form of the battery cells can vary. Battery cells come mainly in cylindrical, prismatic, or pouch forms. With electric vehicles, the prismatic cell is widely used due to its large capacity, thin profile, and effective use of space.
With all this said, cell stack assembly is an obviously complicated and complex process. We are a world-leading provider of multiple bonding and dispensing technologies. With the SCA dispensing product line, we offer solutions to these challenges and, in the process, increase flexibility, productivity, and quality.
The answer lies in a bundled dispensing and integrated vision monitoring system. For the prevailing prismatic battery cells, we recommend cell bonding with a two-component (2C) fast-curing material that does not require external heat for hardening.
Dispensing system for continuous quality assurance in real-time
When applying 2C adhesive materials, mixing is a critical stage. The innovative SCA 2C mixing valve delivers, with high speed, a consistent bead application with a superior mix and metering. The application of the material can be dispensed in different patterns enabling tailored solutions. Regardless of the selected pattern, the material is precisely applied, eliminating air pockets and ensuring electric insolation.
The dispensing system can be equipped with an integrated vision monitoring system for continuous quality assurance. The system monitors the position, width, and continuity of the bead application in real-time, ensuring quality levels and efficiency throughout the process.
Our cell stack assembly solution, combining dispensing and quality monitoring systems, offers high process reliability and flexibility. Features allow for perfect tailoring and adjustment of the process parameters such as flow, pressure, temperature, and mixing ratio. The adjustment possibilities mean less purging thanks to a dispensing process that can be fully aligned with the properties of the selected cell bonding material.
All in all, the result is a solution to cell stack assembly challenges that offer high application speeds and unprecedented process quality with a bubble-free application that ensures full contact and electrical insulation.
Watch the video to learn more about our solution:
