As industry competition intensifies, many photovoltaic (PV) module manufacturers are rapidly entering the energy storage sector, leveraging channel synergies and the advantages of "PV-storage integration" to build a second growth curve.

Compared with specialized energy storage system manufacturers, PV companies are relatively late entrants in the field of cell manufacturing. They face multiple challenges such as a high proportion of new production lines, short process validation cycles, and significant pressure to achieve rapid mass production. Manufacturing processes and consistency have thus become core variables determining product competitiveness.

QUARK Industrial Research Institute has deep roots in the PV industry. Leveraging its expertise in precision dispensing processes and application know-how, it supports the entire lifecycle of energy storage cell manufacturing—from mass production ramp-up to new process validation.

Precision Dispensing Processes Run Through Core Stages of Energy Storage Cell Manufacturing

From cell electrode encapsulation to module structural bonding, from thermal management interface coating to insulation protection, precision dispensing technology is embedded in the key manufacturing steps of energy storage cells—from electrodes to modules.

• Battery Electrode Encapsulation
  Dispensing applications: End-face sealing, edge insulation coating, edge adhesive frame sealing, etc.
  Process challenges: In electrode encapsulation, dispensing accuracy directly determines process feasibility. Especially in flexible substrate applications, substrate deformation can affect accuracy; coating that is too thin, too thick, or leads to adhesive overflow may cause edge leakage or short circuits, or even directly damage the substrate.
  Dispensing requirements: High precision in adhesive thickness (typically 20–150μm). Multi-layer encapsulation requires tighter adhesive width tolerance (±5μm). Additionally, defects such as bubbles and scattered dots must be strictly controlled.
  Primary media: Hot melt adhesive, UV adhesive, etc.

Image: QUARK soft film electrode edge dispensing application case

Image: QUARK electrode insulation frame adhesive case — click image for more process details

• Current Collector Processing
  Dispensing applications: Copper foil functional coating, conductive interface adhesive application, etc.
  Process challenges: Surface coating of current collectors is a key focus of industrialization. Insufficient coating adhesion or uneven coating can affect cycle stability and product lifespan.
  Dispensing requirements: Precision is typically at the sub‑millimeter level. Copper foil and other electrode materials are special and costly, requiring greater dispensing stability and consistency.
  Primary media: Insulating adhesive, conductive adhesive, hot melt adhesive, etc.

Image: QUARK copper foil interface processing application case

• Energy Storage Cell Assembly
  Dispensing applications: Terminal sealing, structural fixation, cell edge reinforcement, etc.
  Process challenges: These processes must balance conductive and insulating requirements. The compact space around terminals can affect dispensing accuracy and efficiency, leading to sealing failure or structural looseness, which may reduce interconnection quality and cycle life.
  Dispensing requirements: Higher bonding precision is needed, along with long‑term stability and consistency. Overall dispensing cycle time is also critical for mass production viability.
  Primary media: Structural adhesive, insulating adhesive, conductive adhesive, hot melt adhesive, etc.

Image: QUARK membrane electrode bonding case — click image for more process details

QUARK Precision Dispensing Supports Advanced Process Validation and Mass Production

To address the process challenges and needs of PV‑industry‑based energy storage cell manufacturing, QUARK Industrial Research Institute provides precision dispensing solutions tailored to different production stages, leveraging its high‑precision dispensing technology and extensive process expertise.

Precision Capabilities:

• Minimum dot diameter: 200μm; minimum line width: 250μm

• Minimum adhesive thickness: 50μm (can reach 20–30μm in experimental environments for certain media)

• Glue width tolerance < 50μm; CPK > 1.67, meeting energy‑storage grade requirements

Efficiency Capabilities:

• Dispensing speed: 200–300 mm/s

• A single controller can drive up to 8 valves, adapting to high‑volume production line cycles

Media Compatibility:

• UV adhesives, thermosetting adhesives, hot melt adhesives, thermal interface materials, structural adhesives, conductive adhesives, insulating adhesives, etc.

• Supports viscosities ranging from 0 to 200,000 mPa·s

Additionally, in response to the growing demand for domestic substitution, QUARK Industrial Research Institute leverages technological innovation to help customers optimize process costs and efficiency. It supports collaborative R&D on production lines, conducts process validation, and provides full‑lifecycle services from prototyping to mass production.

Today, the capacity race in PV‑industry‑based energy storage cell manufacturing has entered a phase where process capability determines success. From 20–30μm insulation layers at electrode edges, to precision patterns on copper foil surfaces, and reliable structural bonding of modules, precision dispensing technology is playing a critical role at the micro‑scale of energy storage cells.

QUARK Industrial Research Institute will continue to help PV‑based energy storage manufacturers overcome process bottlenecks, providing key technical support for process upgrades and mass production ramp‑up.