The world of electromobility and battery manufacturing is rapidly evolving and the manufacturing process demands innovative solutions. Modern electrical vehicles use various types of batteries that must be optimized for longevity, performance, and safety. This makes dispensing solutions an advantageous way to assemble them. Use high-performance adhesives, sealants, or thermal interface materials with an efficient dispensing system to boost production efficiency. Thus, you can also reduce weight as well as costs and drive sustainability.
Six common dispensing challenges in battery assembly processes
Over the years, a number of applications have become common in electric vehicle production processes. It started with applications such as a simple sealing application, known from the engine sealing process. These have now evolved into fast-moving innovations revolutionizing the entire production process.
There are many application processes in battery assembly depending on the battery cell type - cylindrical, prismatic, or pouch - and the battery design.
- Cell and sidewall bonding
- Battery tray sealing
- Thermal management
- Fire protection
- Battery cover sealing
- Corrosion protection
Corrosion protection
At the end of the process, battery manufacturers need to seal the critical areas of the battery to avoid corrosion. State-of-the-art battery designs have many surface breaks, trim edges, and joints. For example, mechanical cover-to-tray joining can cause slight damage to the lid’s coating. At these spots, moisture can enter, and there is a high risk of corrosion. To protect these areas, you can apply anti-corrosion materials such as special waxes.
Challenges in corrosion protection applications:
The application process at the surface of the battery with its many contours, edges, and joints is challenging. Common manual or automated spray applications lead to manual rework, masking effort, and material waste. This affects the productivity and the quality of the corrosion protection process. On top of that, serviceability aspects may need to be considered. If the joining elements are covered with material, loosening the screws for repairs is difficult.
Our solutions for corrosion protection applications:
IDDA.Seal is an intelligent and dynamic drop application that can also process waxes. You can individually control every single droplet. This allows for the highest precision and a fully flexible bead geometry. We can perfectly adjust the bead width and thickness to your requirements. You can apply the material as thinly and precisely as possible. You use only as much material as necessary. Thus, you cut manual rework and material usage to a minimum. For example, you can omit the head of the joining element. This allows clean loosening of the screw for repairs.
Your EV battery manufacturing challenge is our industrial dispensing solution
With our extensive knowledge of industrial trends, challenges and opportunities, our technical experts and our broad network, we can support you in significantly improving your processes, your production and profitability.