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 latecomers in cell manufacturing. They face challenges including a high proportion of new production lines, short process validation cycles, and significant pressure to achieve mass production quickly. 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 precision dispensing process capabilities and application know‑how — including advanced jetting valve technology and integrated dispensing systems — 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 — powered by high‑performance jetting valves and customized dispensing systems — 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 when working with flexible substrates, substrate deformation can affect accuracy. Coatings that are too thin, too thick, or cause adhesive overflow may lead to edge leakage or short circuits, or even directly damage the substrate.
  Dispensing requirements: High adhesive thickness precision (typically 20–150 μm). Multi‑layer encapsulation demands tighter adhesive width tolerance (±5 μm). In addition, defects such as bubbles and satellite dots must be strictly controlled.
  Primary media: Hot melt adhesive, UV adhesive, etc.

Image: QUARK flexible film electrode edge dispensing case

Image: QUARK electrode insulation frame adhesive case 

• Current Collector Processing
  Dispensing applications: Copper foil functional coating, conductive interface adhesive application, etc.
  Process challenges: Surface coating of current collectors is a key direction for industrialization. Insufficient coating adhesion or uneven coating can affect product cycle stability and lifespan.
  Dispensing requirements: Precision is generally sub‑millimeter. Copper foil and other electrode materials are special and costly, requiring greater dispensing stability and consistency — often delivered by precision jetting valves within advanced dispensing systems.
  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 reduces interconnection quality and cycle life.
  Dispensing requirements: Higher bonding precision is required, along with long‑term stability and consistency. Total 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 

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 — incorporating high‑performance jetting valves and flexible dispensing systems — tailored to different production stages.

Precision Capabilities:

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

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

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

Efficiency Capabilities:

• Dispensing speed: 200–300 mm/s

• A single controller can drive up to 8 valve units — ideal for high‑volume production lines using synchronized jetting valve arrays within a unified dispensing system

Media Compatibility:

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

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

*Parameters verified by QUARK LAB; specific process details to be discussed case by case

In addition, 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 — all supported by reliable dispensing systems and robust jetting valve performance.

Today, the capacity race in PV‑industry‑based energy storage cell manufacturing has entered a phase where process capability determines success. From 20–30 μm insulation layers at electrode edges, to precision patterns on copper foil surfaces, and reliable structural bonding of modules, precision dispensing technology — enabled by advanced jetting valves and integrated dispensing systems — 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.