Optical adhesion inspection: Bonding process stable in less than 7 days

A recent in-line application involves the production of battery electric vehicles. Bonded films, when properly adhered, provide electrical insulation and thermal conductivity.

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A special process step required manual application of the die-cut film. For the first time, the operator was provided with an intuitive visualization to monitor and improve his own bonding results. During the production start-up phase, the operator was able to correct the application of the film.

The following graph shows the quality improvement achieved with TENTA. The average delamination (y-axis) of all films during one operator's shift (x-axis) is plotted. The dashed line is the hard limit set for each film.

If 6% delamination was exceeded, the operators for the first 12 shifts had to rework:

• The red line is the result of the rejected parts: Without TENTA, parts with up to 9% delamination would have been produced.

• The green line shows the reworked parts: With TENTA, components with a maximum of 5% delamination were produced.

After 12 layers, the hard limit (dashed line) was reduced to 5% to further improve the quality after the initial operator improvement. A stable bonding process was achieved after only 20 shifts. Components were produced with only 2% to 3% delamination.

All measured values and other data, including photos of the components, are fed into the production plant's MES. TENTA can react remotely and in real time to production drifts or the like, and also immediately adjust limits in line with quality and throughput targets.