Stacking unit for the production of modules or module precursors

Abstract

A stacking unit for the production of modules or module precursors, comprising a first plate, a lifting device, a second plate, and a third plate. The first plate is designed and configured to receive individual layers of material, either individually or in stacks, and comprises a base plate, at least one first section raised from the base plate, and at least one second section raised from the base plate and adjacent to the first section. The first section and the second section are configured to be movable relative to each other. The lifting device is configured to raise and lower the first plate. The second plate and the first plate are displaceable relative to each other, the second plate having at least one first and one second clamping finger.The third plate supports the second plate and is to be coupled to a support arrangement along which the stacking unit can be moved longitudinally or against a conveying direction.

Description

background

[0001] This describes a stacking unit for producing modules or module precursors. These modules or module precursors can be fuel cells or battery cells containing layered material. Details are defined in the claims. The description also contains relevant information on the structure and mode of operation, as well as variants of the device and method.

[0002] As part of efforts to reduce the ecological footprint, demand for alternative drive technologies for vehicles has increased over the past decade. Vehicles that are powered by electricity in addition to the traditional combustion engine are occupying an ever-increasing market share. Two basic energy supply methods are currently available to supply purely electric drives with electrical energy. In one method, the purely electric drive is powered by an electrical energy storage device, e.g., a battery cell. In the second method, electricity is generated from the interaction of hydrogen previously supplied to the vehicle with oxygen drawn in from the air in a fuel cell. Both of these approaches require fuel cell or battery / accumulator cell modules.In the automated production of modules or precursors of modules for fuel or battery cells, the technical problem is to transport and stack the layer materials required for the modules or precursors of modules without causing any damage, so that the resulting stacks can be incorporated into a fuel or battery cell to be manufactured in a later step.

[0003] In conventional stacking units, the material layers are stacked on a flat storage surface, which makes it particularly difficult to remove the layer stack from the stacking unit for further processing without causing any damage. In some variants, the entire layer stack carrier is removed from the stacking unit and transported to the next processing station. However, this represents a cost driver, as more layer stack carriers than stacking units are required.

[0004] DE 10 2022 107 942 A1 relates to a stacking unit for producing modules or precursors of modules, in particular fuel or battery cells containing layered material. At a stacking point, a first lifting device with a receptacle removes an empty workpiece carrier from a central transport line and, after filling, returns it to the central transport line for conveyance to a subsequent process station. One or more stacking devices alternately transport individual anode layers and individual cathode layers to the stacking point to form an electrode stack and stack them on the workpiece carrier located at the stacking point. A first and a second clamping finger engage the uppermost of the anode and cathode layers and press them against the electrode stack.

[0005] JP 2014 078464 A relates to a laminating machine for producing a laminated body from a rectangular foil as a positive electrode and a rectangular foil as a negative electrode, which are alternately laminated over a rectangular release film. A conveyor serves to sequentially pick up and convey the cathode foil, the anode foil, and the release film to a predetermined stacking position and to align and stack the cathode foil, the anode foil, and the release film at the stacking position. Four first holding members are arranged at the four corners of the laminated body to be stacked at the stacking position and serve to press the four corners of the cathode foil, which are transported to and placed by the conveyor at the stacking position, or the four corners of the release film, which are transported to and placed by the conveyor at the stacking position, from above to stack them under the cathode foil.First horizontal displacement means can displace the position of the first holding elements in the horizontal direction from a retracted position at least outside the cathode foil or the separator foil to a holding position corresponding to the four corners of the cathode foil or the separator foil. A first vertical displacement means serves to displace the position of the first holding element in the vertical direction from a released position, which is separated at least upwardly from the cathode foil or the separator foil, to a contact position capable of contacting the cathode foil or the separator foil.Four second holding members are provided at the four corners of the laminated body to be stacked at the stacking position, for pressing the four corners of the negative electrode foil located at the stacking position or the four corners of the separator foil located at the stacking position from above to be stacked under the negative electrode foil. Second horizontal displacement means are provided for horizontally shifting the position of the second holding members from a retracted position at least outside the anode foil or the separator foil to a holding position corresponding to the four corners of the anode foil or the separator foil.The second displacement devices for displacement in the vertical direction serve to shift the position of the second holding element in the vertical direction from a position that is at least upwardly separated from the anode foil or the separator foil to a contact position in which the second holding element contacts the anode foil or the separator foil. When a new cathode foil, anode foil, or separator foil is conveyed and brought into the stacking position, the newly placed cathode foil, anode foil, or separator foil is held down by the four corners of the cathode foil, anode foil, or separator foil already placed underneath. After the four first or second holding elements are pulled out, the four corners of the newly placed cathode foil, anode foil, or separator foil are held firmly by the corresponding four first or second holding elements.The four corners of the newly placed cathode foil, anode foil, or separator are pressed by four corresponding first or second holding members. The height of the first and second holding members when moving from the holding position to the holding position is set to be higher than the height of the first and second holding members when returning from the holding position to the retraction position. The strokes of the holding members when holding down the cathode foil, anode foil, or separator film during the movement from the holding position to the retraction position are higher than the strokes when moving from the holding position to the retraction position.

[0006] WO 2021 171 946 A1 relates to a testing device for checking the position of the electrode layer in a laminate in which a release film and an electrode layer are bonded by an adhesive, from the release film side. An infrared irradiation unit irradiates the laminate with infrared light from the release film side. A camera sensitive to infrared light records the infrared light transmitted through the release film and reflected by the electrode layer. A detection unit detects the position of the electrode layer based on the image captured by the camera.

[0007] WO 2021 171 946 A1 also relates to a stacking table on which laminate stacks consisting of release liners and electrode layers are stacked. A transport unit is used to transport the release liners and electrode layers and place them on the stacking table. The above-mentioned testing device checks the position of the electrode layer in the laminate stack released by the transport unit.

[0008] DE 10 2017 216 152 A1 relates to a stacking device for multilayer flat electrode stacks, wherein the stacking device is movable in the Y direction and comprises a removable carrier. Furthermore, the invention relates to a battery cell and a use thereof.

[0009] US 2014 / 0241849 A1 relates to a cart having a support surface with a selectively adjustable contour to provide substantially uniform support of a load (e.g., a stack of print media sheets) in receiving and storage modes and to facilitate transfer of the load to another support surface in transfer mode. The cart may comprise a support surface with alternating fixed and movable sections. In receiving and storage modes, the movable sections may be aligned with the fixed sections so that the support surface has a substantially planar contour, thus providing substantially uniform support. In transfer mode, the movable sections may be lowered so that the support surface has a corrugated contour to facilitate load transfer (e.g., using an interdigitation technique).Furthermore, a sheet stacker for a printing system having such a carriage for receiving, storing and transferring a stack of sheets and associated methods are disclosed.

[0010] CN 114024041 A relates to a lamination production line with platform circulation supply, which consists of a lamination mechanism, a lamination platform, a drive mechanism, lifting mechanisms, slide rails, and a rubber coating unloading mechanism. The slide rails include an upper slide rail and a lower slide rail arranged vertically parallel and spaced apart. Lifting stations are arranged on both sides of the upper slide rail and on both sides of the lower slide rail, respectively. A laminating station is arranged on the upper slide rail, and an unloading station is arranged at one end of the lower slide rail. The laminating platform is slidably mounted on the slide rails. The two lifting mechanisms are arranged at the lifting stations on both sides, respectively.The drive mechanism is located at the laminating station, and the laminating mechanism is located above the laminating station. The rubber pad unloading mechanism is located on the outside of the unloading station. Underlying problem

[0011] Based on this, a cost-effective and robust arrangement of a stacking unit and a method for stacking layer material and for removing the layer stack at high processing speed are to be provided in order to manufacture modules or precursors of modules, for example of fuel or battery cells containing layer material, with high precision. Proposed solution

[0012] The solution to the problem is achieved by the subject matter of the appended independent patent claims. The following solution is disclosed in method and device aspects, with the device aspects also relating to the method and vice versa.

[0013] A stacking unit for producing modules or precursors of modules is provided. The stacking unit comprises a first plate. The first plate is intended and configured to receive individual material layers individually or in stacks in order to form a layer stack thereon. The first plate comprises a base plate. The first plate further comprises at least one first partial section raised from the base plate. The first plate further comprises at least one second partial section raised from the base plate and adjacent to the first partial section. The at least one first partial section has at least one first storage surface for the material layers. The at least one second partial section has at least one second storage surface for the material layers. The at least one first partial section and the at least one second partial section are configured to be movable relative to one another.In a first orientation of the sections for depositing the material layers, the at least one first section and the at least one second section form a common, substantially completely flat, depositing surface. In a second orientation for removing the stack of layers from the stacking unit, the at least one first section and the at least one second section form a free space between the first depositing surface and the second depositing surface. The stacking unit further comprises a lifting device. The lifting device is configured to raise and lower the first plate. The stacking unit further comprises a second plate. The first plate and the second plate are displaceable relative to one another. The second plate comprises at least one first and one second clamping finger. The clamping fingers are configured to engage with the uppermost material layer located on the first plate.The clamping fingers are further configured to press the respective topmost material layer against the first plate or the layer stack located thereon. The stacking unit further comprises a third plate. The third plate is configured to support the second plate. The third plate is coupled to a support arrangement. The stacking unit is movable along the support arrangement. The stacking arrangement is movable longitudinally or counter to a conveying direction.

[0014] In this case, raising the first plate by the lifting device means increasing the distance between the first plate and the second plate. Lowering the first plate by the lifting device means decreasing the distance between the first plate and the second plate.

[0015] The stressed stacking unit significantly facilitates the non-destructive and damage-free removal of the layer stack from the stacking unit. By creating a free space between the first and second depositing surfaces, removal fingers can reach under the layer stack and lift it from the stacking unit. Only the weight of the layer stack rests on the removal fingers. In commercially available stacking units with a flat depositing surface, removing the layer stack requires either lateral pressure to clamp the layer stack between lateral clamping jaws, or the removal fingers must be pushed between the flat depositing surface and the underside of the layer stack, which can lead to damage to the bottommost layer of material.In still other variants, the entire layer stack carrier is removed from the stacking unit to remove the layer stack, which leads to unnecessarily high material expenditure and high costs, since more material layer carriers than stacking units are required.

[0016] The first plate, which can be raised and lowered by the lifting device, offers the advantage that the stacking unit's storage surface, or the topmost material layer as the new storage surface, always maintains a constant distance from the conveyor system transporting the material layers once material layers are stacked in the stacking unit. Furthermore, by lowering the first plate, layer stacks of varying thicknesses can be produced.

[0017] The at least one first subsection can at least partially form an edge of the first plate. The at least one second subsection can at least partially form an edge of the first plate.

[0018] The at least one first subsection and the at least one second subsection can be configured to be movable relative to one another such that, in the second orientation for removing the layer stack from the stacking unit, they form a free space between the layer stack and the first storage surface or the second storage surface.

[0019] The at least one first subsection can be configured to be movable relative to the at least one second subsection, wherein the at least one second subsection is immovable.

[0020] The at least one second subsection can be configured to be movable relative to the at least one first subsection, wherein the at least one first subsection is immovable.

[0021] The at least one first subsection can comprise a vacuum bed. The at least one first support surface can at least partially comprise a microporous first support. The at least one first subsection can receive the first material layer using a pneumatically controlled vacuum. The vacuum bed can be subjected to overpressure and emit a short overpressure pulse.

[0022] The vacuum bed in at least one first section offers the advantage that the first deposited layer of material is sucked onto the depositing surface, thus preventing unwanted slippage. Conversely, the vacuum bed offers the possibility of creating an air gap / air cushion between the depositing surface and the stack of layers when subjected to overpressure or, for example, a short overpressure pulse, thus further facilitating the removal of the stack of layers.

[0023] The first plate and the second plate can be arranged substantially parallel to each other. A first geometric axis extending through the center of the first plate and oriented perpendicular to the first plate can be aligned identically to a second geometric axis extending through the center of the second plate and oriented perpendicular to the second plate.

[0024] The first plate and the third plate can be arranged substantially parallel to each other. A first geometric axis extending through the center of the first plate and oriented perpendicular to the first plate can be aligned identically to a third geometric axis extending through the center of the third plate and oriented perpendicular to the third plate.

[0025] The second plate and the third plate can be arranged substantially parallel to each other. A second geometric axis extending through the center of the second plate and oriented perpendicular to the second plate can be aligned identically to a third geometric axis extending through the center of the third plate and oriented perpendicular to the third plate.

[0026] A parallel arrangement of the first and second plates, as well as the first and third plates and the second and third plates, with identically aligned geometric axes running through the center of each plate, offers the advantage of achieving the most space-saving geometry of the stacking unit. Furthermore, this arrangement of the first and second plates enables a symmetrical arrangement of the clamping fingers on the second plate, thus ensuring symmetrical pressure loading by the clamping fingers on the top material layer.

[0027] The lifting device can comprise a drive. The lifting device can further comprise a lifting rod oriented perpendicular to the first plate. The lifting rod can be arranged perpendicular to the conveying direction. The lifting rod can be connected at one side to the side of the first plate facing the second plate. The lifting rod can be gear-connected to the drive.

[0028] The second plate may have a passage for the lifting rod. The third plate may have a passage for the lifting rod. The drive may be arranged on the side of the third plate facing away from the second plate.

[0029] The lifting device can be configured to lower the first plate by a certain distance when stacking the individual material layers. This distance can correspond to the thickness of a single material layer.

[0030] The at least one first and second clamping finger can be movable perpendicular to the conveying direction. The at least one first and second clamping finger can be arranged on the side of the second plate facing away from the first plate. An arrangement of the at least one first and second clamping finger on the side of the second plate facing away from the first plate offers the advantage that the first plate can be lowered until it rests completely on the second plate when stacking the material layers, so that either the greatest possible thickness of the layer stack can be increased while maintaining the same design of the stacking unit, or the design of the stacking unit can be reduced while maintaining the same greatest possible thickness of the layer stack.

[0031] The second panel may comprise a lightweight panel. The third panel may comprise a lightweight panel. The lightweight panel may have a honeycomb structure. The lightweight panel may have a multi-layer structure. The lightweight panel may be made of a metal. The lightweight panel may be made of a plastic. The lightweight panel may be made of a fiber fabric. The lightweight panel may, for example, comprise two carbon fiber panels with a honeycomb structure in between. The honeycomb structure may, for example, comprise or be formed as an aluminum honeycomb structure or an aramid honeycomb structure.

[0032] If the second and / or third plate comprises a lightweight plate, this leads to a reduction in the overall weight of the stacking unit and thus to a reduction in the moving mass when the stacking unit is moved along the support arrangement or when movements within the stacking unit, such as raising and lowering the first plate, are performed. Further advantages include reduced vibrations, thus increasing the positioning accuracy of the stacking unit itself and the material layers on the support surface, and reducing heat input into the components compared to a solid metal plate.

[0033] The use of a honeycomb structure in the lightweight panel offers high stability while maintaining low weight. A multi-layer construction of the lightweight panel, such as two carbon fiber panels with a honeycomb structure in between, further increases stability and achieves a flat panel surface.

[0034] The dimensions of the first plate can be adapted to the dimensions of a first material layer. The dimensions of the second plate can be adapted to the dimensions of a first material layer.

[0035] If the dimensions of the first plate and the second plate are adapted to the dimensions of a first material layer (ML), the mass of the stacking unit and the individual movable components to be moved is reduced to the minimum necessary for processing the first material layer (ML). This leads, on the one hand, to a reduction in vibration and heat input, and, on the other hand, to an increase in the positioning accuracy of the stacking unit and the storage area.

[0036] The first plate and the second plate can be designed as a single unit that can be removed from the stacking unit. The unit can be connected to the stacking unit by detachable connections. The unit can be connected to the stacking unit by easily detachable connections, such as plug-in connections and quick-release fasteners.

[0037] The first plate can be designed as a unit that can be removed from the stacking unit. The unit can be connected to the stacking unit by detachable connections. The unit can be connected to the stacking unit by easily detachable connections, for example, plug-in connections and quick-release fasteners.

[0038] A removable unit consisting of the first plate and the second plate, or just the first plate, offers the advantage that the unit, whose dimensions are adapted to the dimensions of a first material layer, can be exchanged for another unit with dimensions adapted to the second dimensions of a material layer. Thus, a unit adapted to the dimensions of a material layer can always be used without requiring a separate stacking unit for each material layer with different dimensions. This increases flexibility and efficiency in the production of modules or precursors of modules while simultaneously reducing manufacturing costs.

[0039] The unit comprising the first plate and the second plate may be interchangeable with another unit having dimensions adapted to the dimensions of a second material layer.

[0040] Cables and lines for supplying the drives and the vacuum bed of the first plate can enter the stacking unit through a channel below the third plate. Cables and lines for supplying the drives of the second plate can enter the stacking unit through a channel below the third plate. The channel can be attached to the side of the third plate facing away from the second plate. The channel can include a cable guide or drag chain.

[0041] The cables and lines for supplying the drives and the vacuum bed of the first plate and the second plate may include data lines, pneumatic lines and power lines.

[0042] A method is used to produce modules or precursors of modules in a stacking unit, wherein the stacking unit comprises a first plate, a second plate, a third plate and a lifting device. The first plate comprises a base plate. The first plate further comprises at least one first partial section raised from the base plate. The first plate further comprises at least one second partial section raised from the base plate and adjacent to the first partial section. The at least one first partial section has at least one first storage surface. The at least one second partial section has at least one second storage surface. The at least one first partial section and the at least one second partial section are designed to be movable relative to one another. The second plate comprises at least one first and one second clamping finger. The third plate supports the second plate.The third plate is to be coupled to a support assembly. The stacking unit is to be moved along the support assembly, either longitudinally or counter to a conveying direction. The method comprises the following steps, possibly in a different order: - moving the at least one first sub-section and the at least one second sub-section into a first orientation in which the at least one first sub-section and the at least one second sub-section form a common, substantially continuously flat storage surface for depositing the material layers; - placing the at least one layer of material on the common, substantially continuously flat storage surface; - lowering of the first plate by the lifting device during or after the individual layer of material has been laid down by a distance corresponding to the thickness of an individual layer of material; - Pressing the top layer of material on the first plate against the first plate or the stack of layers on it by means of the clamping fingers; - moving the at least one first sub-section and the at least one second sub-section into a second orientation in which the at least one first sub-section and the at least one second sub-section form a free space between the first storage surface and the second storage surface for removing the layer stack from the stacking unit; - Inserting removal fingers into the space between the first storage surface and the second storage surface; - Removing the stack of layers from the stacking unit using the removal fingers. Short description of the drawings

[0043] Further details, features, advantages, and effects of the arrangements and procedures described herein are evident from the following description of currently preferred variants and from the drawings. These show: Fig. 1 a stacking unit for producing modules or precursors of modules in a schematic side view; Fig. 2a a first plate of the stacking unit Fig. 1 in a schematic plan view; Fig. 2b shows a first plate in a first orientation of the subsections in a schematic side view; Fig. 2c a first plate in a second orientation of the subsections in a schematic side view; Fig. 3 a third plate of the stacking unit Fig. 1 in a schematic plan view; Fig. 4a a lightweight panel in a schematic plan view; Fig. 4b a lightweight panel in a schematic side view. Detailed description of the drawings

[0044] In the following description, the definition applies that the directions x, y, z shown in the figures form an orthogonal coordinate system, i.e. the direction x is orthogonal to the direction y and the direction z, and the direction y is orthogonal to the direction z. Furthermore, the directions x and y span a horizontal plane and the direction z forms the vertical to the horizontal plane. In the figures, the height of a component is defined by its extension in the z-direction, its length by its extension in the x-direction and its width by its extension in the y-direction. A component is considered to be arranged above another component if the component is arranged behind the other component in the z-direction. All proportions and dimensions of the components shown in the figures are not to scale. Individual components may be shown greatly enlarged.This is for the sake of clarity, but the subject matter of the present disclosure is not limited to this definition and the associated orientation of the stacking unit.

[0045] In Fig. 1 schematically shows the structure of a stacking unit 100 for producing modules or precursors of modules.

[0046] The stacking unit 100 comprises a horizontally oriented first plate 200 with a rectangular base plate 230. The first plate 200 can, for example, comprise a lightweight panel 700 or be designed as such. The base plate 230 can have other shapes and is not limited to a rectangular shape. A first sub-section 210 is applied to the base plate 230, which is raised from the base plate 230 and which, in turn, has a first storage surface 211 on its upper side for receiving the material layers ML (not explicitly shown here). In the exemplary embodiment shown here, a total of four rows of two first sub-sections 210 are arranged in the longitudinal direction on the base plate 230. Due to the side view, only the first four sub-sections 210 of the four rows are visible. A detailed overview and explanation follows with the description of the Fig. 2a.

[0047] The eight first sections 210 comprise a vacuum bed, and their first storage surfaces 211 comprise a microporous storage. The respective vacuum bed generates a negative pressure p-- in the respective storage surface 211, whereby a first material layer is sucked onto the storage surface during storage and is thereby fixed in position. Furthermore, by applying opposite pressure, e.g., by applying a brief overpressure pulse to the vacuum bed, an air gap can be created between a finished layer stack LS and the storage surface 211, thereby facilitating the removal of the layer stack LS from the stacking unit 100.

[0048] In the example shown here, a second subsection 220 raised from the base plate 230 is applied between the first subsections 210. The second subsection 220 is arranged and configured adjacent to the eight first subsections 210 such that, in a plan view, almost the entire surface of the base plate 230 is covered by the first subsections 210 and the second subsection 220. The disclosed subject matter is not limited to the number and arrangement of the first subsections 210 and the second subsections 220 described here, so that further combinations are possible.

[0049] The second subsection 220 has a second storage surface 221 on its upper side for receiving the material layers ML (not explicitly shown here). Furthermore, the second subsection 220 is designed to be movable in the vertical direction. The movement of the second subsection 220 in connection with the storage of the material layers ML and the removal of the layer stack LS is described in detail in the Fig. 2b - 2c explained.

[0050] The first plate 200 is connected or coupled at its underside and in the center of its horizontal extension to a lifting rod 510 belonging to the lifting device 500, wherein the lifting rod 510 carries the first plate 200.

[0051] The stacking unit 100 further comprises a horizontally oriented, rectangular second plate 300, which is arranged parallel below the first plate 200. The second plate 300 can, for example, comprise a lightweight panel 700 or be designed as such. A geometric axis A' running through the center of the second plate 300 and oriented vertically is identical to a geometric axis A running through the center of the first plate 200 and oriented vertically. In other words, the centers of the first plate 200 and the second plate 300 lie directly above one another. However, the subject matter of the disclosure is not limited to the rectangular shape of the second plate 300 or the arrangement of the second plate 300 relative to the first plate 200 described here.

[0052] The second plate 300 comprises at least two clamping fingers 310, which are configured to engage the uppermost material layer ML located on the first plate 200 and to press it against the first plate 200 or the layer stack LS located thereon. The clamping fingers 310 are attached to the underside of the second plate 300 facing away from the first plate 200, since this allows the first plate 200 to be lowered until it rests essentially on the second plate 300. The raising and lowering of the first plate 200 in connection with the deposition of material layers ML will be explained in detail later in this description of the figures.

[0053] The clamping fingers 310 are arranged opposite one another. With more than two clamping fingers 310, for example, four clamping fingers 310, the clamping fingers 310 are arranged on both sides of the second plate 300 in width, each two times two clamping fingers 310. However, the present disclosure is not limited to an arrangement of the clamping fingers 310 in the width direction. An arrangement in the longitudinal direction or, for example, an asymmetric arrangement of the clamping fingers 310 is also possible.

[0054] The clamping fingers 310 have actuators (not explicitly shown here) that can move the clamping fingers 310 in the x-direction and in the z-direction. All shown and described movabilities in the x-, y-, or z-direction are defined bidirectionally, i.e., movability in the x-direction simultaneously defines movability opposite to the x-direction. Movability in the x-direction enables the clamping fingers 310 to engage or disengage from the topmost material layer ML, and movability in the z-direction enables the topmost material layer ML to be pushed onto the storage surface or the layer stack LS located thereon. In the embodiment shown here, the clamping fingers 310 are made of spring steel in order to exert a resilient load on the material layers.

[0055] The second plate 300 has a central passage for the lifting rod 510 belonging to the lifting device 500.

[0056] The stacking unit further comprises a horizontally oriented, rectangular third plate 400, which supports the second plate 300. The third plate 400 can, for example, comprise or be designed as a lightweight plate 700. The third plate 400 has a central passage for the lifting rod 510 belonging to the lifting device 500.

[0057] A cylindrical support tube 410 is connected to the third plate 400 in such a way that the support tube 410 projects into the central passage of the third plate 400 or completely penetrates it, thus forming a spacer ring between the third plate 400 and the lifting rod 510 penetrating the central passage, wherein the support tube 410 is firmly connected to the third plate 400. The support tube 410 can be connected or coupled to the second plate 300 in such a way that the second plate 300 rests on the outer walls of the upper side of the support tube 410 and the hollow space of the support tube 410 on the inside of the tube is aligned with the central passage of the second plate 300.

[0058] The third plate 400 is connectable to a support arrangement 420. In the Fig. In the embodiment shown in Figure 1, the support arrangement 420 comprises two pairs of rails. To move the stacking unit 100 along the support arrangement 420 in or against a conveying direction R, here the y-direction, permanent magnets 441 are mounted on the respective rails of the rail pairs, and two electromagnetic rotors of electric direct drives 440 with current-carrying coils are mounted on the underside of the third plate 400. However, any desired variants of support arrangements 420 for moving the stacking unit 100 are also conceivable, for example, a conveyor belt.

[0059] The stacking unit 100 further comprises the lifting device 500 with the lifting rod 510 and a drive 520. The lifting device 500 is configured to raise and lower the first plate 200. The lifting rod 510 is connected or coupled on one side to the underside of the first plate 200, whereby the lifting rod supports the first plate 200. Furthermore, the lifting rod 510 is gear-connected to the drive 520. The lifting rod 510 can, for example, be a gear rod that engages with a gear of the drive 520.

[0060] The drive 520 can, for example, be an electric drive and is in the Fig. 1, it is arranged below the third plate 400. The lifting rod 510 penetrates the third plate 400 and the second plate 300 in the central passages provided for this purpose and is arranged within the support tube 410.

[0061] The dimensions of the first plate 200 and the second plate 300 are adapted to the dimensions of a first material layer ML. In particular, a common storage surface consisting of the first storage surface 211 and the second storage surface 221 is adapted to the dimensions of the first material layer ML. Furthermore, the dimensions and mobility of the clamping fingers 310 of the second plate 300 in the x- and z-directions are adapted to the dimensions of the material layers ML. As a result, the total moving mass of the stacking unit 100 is reduced to the minimum required for processing the first material layer ML, thus reducing the vibrations and heat generation occurring in the stacking unit 100.

[0062] The first plate 200 and the second plate 300 are designed as a unit that can be removed from the stacking unit 100. The unit consisting of the first plate 200 and the second plate 300 can be exchanged for another unit with dimensions adapted to the dimensions of a second material layer ML.

[0063] The movement sequence of the first plates 200 and the clamping fingers 310 in connection with the deposition of the material layers ML is explained in more detail below. The first deposition surfaces 211 of the eight first sections 210 and the second deposition surface 221 of the one second section 220 form a common, essentially continuously flat deposition surface. A detailed description of this can be found in the description of the Fig. 2b and Fig. 2c.

[0064] A conveyor device (not explicitly shown here), which is horizontally aligned and arranged at a fixed distance above the stacking unit 100, transports a material layer ML to the common storage surface 211 / 221. The clamping fingers 310 are located in the horizontally outermost position, i.e., the clamping fingers 310 are horizontally furthest away from the horizontal center of the second plate 300 and do not project onto the common storage surface 211 / 221. The first material layer ML is deposited onto the common storage surface 211 / 221 and is sucked onto the common storage surface 211 / 221 by a pneumatically controlled negative pressure p-- of the negative pressure beds in the first subsections 210.

[0065] The clamping fingers 310 move to a horizontally further inward position, i.e., closer to a center of the second plate 300, and thus engage the material layer ML. The actuators 308 and 312 of the clamping fingers 310 (not shown in detail) move the clamping fingers 310 vertically up and down as well as laterally, thus pushing the material layer ML onto the common storage surface 211 / 221.

[0066] The lifting device 500 now lowers the first plate 200 by a distance approximately corresponding to the thickness / height of the first material layer ML. The top side of the first material layer ML now forms the new storage surface for the next material layer ML. By lowering the first plate 200 by the lifting device 500, the distance of the storage surface, now the surface of the material layer ML, from the conveyor device always remains constant.

[0067] These steps are repeated until a desired thickness / height of the layer stack LS is reached.

[0068] Fig. Figure 2a shows schematically the structure of the first plate 200 of the stacking unit 100 from the Fig. 1 in a top view.

[0069] The eight first sections 210 are arranged in four rows of two first sections 210 each in the longitudinal direction on the base plate 230. The one second section 220 is arranged and configured adjacent to the eight first sections 210 such that substantially the entire base plate 230 is covered by the first sections 210 and the second section 220. For reasons of clarity, the first storage surfaces 211 and the second storage surface 221 are not explicitly shown.

[0070] The second subsection 221 is designed to be movable in the vertical direction. In the illustrated embodiment, the second subsection 221 protrudes beyond the base plate 230 on both sides in the x-direction and is connected to two drives 222 attached to the first plate 200, which are configured to raise and lower the second subsection 221. Both the first subsections 210 and the one second subsection 220 form part of the edge of the first plate 200, i.e., at least a part of each first subsection 210 and the second subsection 220 forms the outermost region of the first plate 200 in the horizontal direction.

[0071] Fig. 2b shows schematically the first plate 200 of Fig. 1 in a first alignment of sections 210 / 220 to each other.

[0072] In the first orientation for depositing the material layers ML, the second section 220 is formed by the Fig. 2a, so that the first support surface 211 and the second support surface 221 provide a common, substantially continuously flat support surface. A substantially continuously flat support surface means that the second support surface 221 is brought to the same height as the first support surface 211 by the drive, whereby machine tolerances of the adjustment accuracy are included here. Furthermore, a substantially continuously flat support surface also includes gaps due to horizontal distances between the first section 210 and the second section 220.

[0073] In the first alignment of the sections 210 / 220, the material layers ML are deposited on the common deposit surface 211 / 221 and form a layer stack LS, whereby the first material layer ML is sucked onto the common deposit surface 211 / 221 by the vacuum bed in the first sections 211 and is thus fixed.

[0074] For removing a finished layer stack LS, the first sections 210 and the second section 220 are aligned in a second orientation to each other, as shown in Fig. 2c shown.

[0075] The second subsection 220 is moved vertically downward by the drive 222 until the underside of the second subsection 220 rests on the base plate 230. This creates a free space 240 between the first storage surface 211 and the second storage surface 221, as well as between the second storage surface 221 and the layer stack LS. Because the second subsection 220 at least partially forms an edge of the first plate 200, the resulting free space 240 is accessible from outside the first plate 200. To remove the layer stack LS, removal fingers 250 reach into the free space 240. The removal fingers 250 extend in the y-direction down to below the layer stack LS. The respective vacuum bed in the first subsections 210 is switched off, so that the first material layer ML is no longer sucked onto the shared storage surface 211 / 221.In addition, a brief overpressure pulse can be emitted by the respective vacuum beds to compensate for any remaining negative pressure and thus any residual suction force, and to release the layer stack LS from the common storage surface 211 / 221. The removal fingers 250 then lift the layer stack LS vertically from the common storage surface 211 / 221 and transport it to another process station.

[0076] Fig. 3 shows schematically the structure of the third plate 400 from Fig. 1 in a top view.

[0077] The third plate 400 has a central passage for the lifting rod 510. The lifting rod 510 is located within the support tube 410, with the support tube 410 supporting the second plate 300 and further forming a spacer ring between the third plate 400 and the lifting rod 510. Further arrangements of the support tube 410, such as four individual support tubes 410 arranged at the corners of the third plate 400, which are designed solely to support the second plate 300, are another alternative.

[0078] The third plate 400 is with the Fig. 1, comprising two pairs of rails, along which the stacking unit 100 is to be moved in or against the conveying direction R, here the y-direction.

[0079] The cables and lines for supplying the drives and the vacuum bed of the first plate 200 and the second plate 300 run into the stacking unit 100 in a channel 430 centrally located below the third plate 400. In the example shown, the channel 430 is a drag chain / energy guide chain that is attached directly to the underside of the third plate 400. However, the channel 430 can also be attached indirectly to the third plate 400 and not run centrally into the stacking unit 100. The cables and lines include, for example, (sensor) data, pneumatic, and power lines.

[0080] The Fig. 4a and Fig. 4b schematically shows the structure of a multilayer lightweight panel 700 in a top view and a side view. For clarity, the top panel 720 has been omitted from the top view.

[0081] The lightweight panel 700 in the illustrated embodiment comprises three layers, with a honeycomb structure layer 710 enclosed by two flat panels 720. The honeycomb structure layer can comprise, for example, an aramid or aluminum honeycomb structure. The panels 720 enclosing the honeycomb structure layer can be, for example, carbon fiber panels.

[0082] The variants of the device described above, their construction and operating aspects, as well as the variants of the procedure, serve only to improve understanding of the structure, mode of operation, and properties; they do not limit the disclosure to the exemplary embodiments. The figures are partly schematic. Key properties and effects are sometimes shown significantly enlarged in order to clarify the functions, operating principles, technical designs, and features. Each mode of operation, each principle, each technical design, and each feature disclosed in the figures or in the text can be integrated with all claims, each feature in the text, and in the other figures., other modes of operation, principles, technical embodiments and features contained in this disclosure or resulting therefrom can be freely and arbitrarily combined so that all realistic combinations can be assigned to the described procedure. This also includes combinations between all individual embodiments in the text, i.e. in every section of the description, in the claims and also combinations between different variants in the text, in the claims and in the figures. The claims also do not limit the disclosure and thus the possible combinations of all the features shown with one another. All disclosed features are explicitly disclosed here, both individually and in combination with all other features.

Claims

[1] A stacking unit (100) for producing modules or precursors of modules comprising: - a first plate (200) which is provided and arranged to receive individual material layers (ML) individually or in stacks in order to form a layer stack (LS) thereon, wherein -- the first plate (200) comprises a base plate (230), at least one first section (210) raised from the base plate (230) and at least one second section (220) raised from the base plate (230) and adjacent to the first section (210), wherein -- the at least one first subsection (210) has at least one first storage surface (211) and the at least one second subsection (220) has at least one second storage surface (221) for the material layers (ML), and wherein -- the at least one first sub-section (210) and the at least one second sub-section (220) are designed to be movable relative to one another and thus form a common, substantially continuously flat, depositing surface in a first orientation of the sub-sections (210, 220) for depositing the material layers (ML), and form a free space (240) between the first depositing surface (211) and the second depositing surface (221) in a second orientation for removing the layer stack (LS) from the stacking unit (100); - a lifting device (500) adapted to raise and lower the first plate (200); - a second plate (300), wherein the second plate (300) and the first plate (200) are displaceable relative to each other, wherein -- the second plate (200) has at least a first and a second clamping finger (310), wherein -- the clamping fingers (310) are designed to engage with the respective uppermost material layer (ML) located on the first plate (200) and to press it against the first plate (200) or the layer stack (LS) located thereon; and - a third plate (400) carrying the second plate (300), wherein the third plate (400) is to be coupled to a carrier arrangement (420) along which the stacking unit (100) is to be moved along or counter to a conveying direction (R). [2] The stacking unit (100) according to claim 1, wherein the at least one first section (210) and the at least one second section (220) each at least partially form an edge of the first plate (200). [3] The stacking unit (100) according to one of the preceding claims, wherein the at least one first sub-section (210) and the at least one second sub-section (220) are configured to be movable relative to one another such that, in the second orientation for removing the layer stack (LS) from the stacking unit (100), they form a free space between the layer stack (LS) and the first storage surface (211) or the second storage surface (221). [4] The stacking unit (100) according to any one of the preceding claims, wherein the at least one first section (210) comprises a vacuum bed. [5] The stacking unit (100) according to claim 4, wherein the at least one first storage surface (211) of the first subsection (210) at least partially comprises a microporous first storage. [6] The stacking unit (100) according to one of the preceding claims, wherein the at least one first section (210) receives the first material layer (ML) with a pneumatically controlled negative pressure (p--). [7] The stacking unit (100) according to any one of the preceding claims, wherein - the first plate (200) and the second plate (300) are arranged substantially parallel to each other, and wherein - a first geometric axis (A) passing through the center of the first plate (200) and oriented perpendicular to the first plate (200) is aligned substantially coaxially with a second geometric axis (A') passing through the center of the second plate (300) and oriented perpendicular to the second plate (300). [8] The stacking unit (100) according to any one of the preceding claims, wherein the lifting device (500) comprises a drive (520) and a lifting rod (510) oriented perpendicular to the first plate (200). [9] The stacking unit (100) according to claim 8, wherein the lifting rod (510) is connected at one side to the side of the first plate (200) facing the second plate (300) and is geared to the drive (520). [10] The stacking unit (100) according to claim 9, wherein the second plate (300) and the third plate (400) have a passage for the lifting rod (510) and the drive (520) is arranged on the side of the third plate (400) facing away from the second plate (300). [11] The stacking unit (100) according to one of the preceding claims, wherein the lifting device (500) is configured to lower the first plate (200) during stacking of the individual material layers (ML) by a distance which substantially corresponds to a thickness of an individual material layer (ML). [12] The stacking unit (100) according to any one of the preceding claims, wherein the second plate (300) and / or the third plate (400) comprises a lightweight plate (700). [13] The stacking unit (100) according to claim 12, wherein the lightweight panel (700) has a honeycomb structure (710) and / or a multi-layer construction; and / or comprises two carbon fiber panels (720) with a honeycomb structure (710) in between. [14] The stacking unit (100) according to any one of the preceding claims, wherein the first (200) and the second (300) plate are adapted in their dimensions to dimensions of a first material layer (ML). [15] The stacking unit (100) according to any one of the preceding claims, wherein the first (200) and the second (300) plate are formed as a unit removable from the stacking unit (100). [16] The stacking unit (100) according to claims 14 and 15, wherein the unit comprising the first plate (200) and the second plate (300) is interchangeable with another unit having dimensions adapted to dimensions of a second material layer (ML). [17] The stacking unit (100) according to one of claims 6 to 16, wherein cables and lines for feeding the drives and the vacuum bed of the first (200) and second (300) plate run into the stacking unit (100) in a channel (430) below the third plate (400), and the channel (430) is attached to the side of the third plate (400) facing away from the second plate (300). [18] A method for producing modules or precursors of modules in a stacking unit (100), wherein the stacking unit (100) comprises a first plate (200), a second plate (300), a third plate (400) and a lifting device (500), wherein - the first plate comprises a base plate (230), at least one first sub-section (210) raised from the base plate (230), and at least one second sub-section (220) raised from the base plate (230) and adjacent to the first sub-section (210), wherein the at least one first sub-section (210) has at least one first storage surface (211) and the at least one second sub-section (220) has at least one second storage surface (221), and wherein the at least one first sub-section (210) and the at least one second sub-section (220) are designed to be movable relative to one another, - the second plate (300) comprises at least a first and a second clamping finger (310), - the third plate (400) carries the second plate (300) and is to be coupled to a carrier arrangement (420), and along which the stacking unit (100) is to be moved along or counter to a conveying direction (R); and wherein the method comprises the following steps, optionally in a different order: i) moving the at least one first sub-section (210) and the at least one second sub-section (220) into a first orientation in which the at least one first sub-section (210) and the at least one second sub-section (220) form a common, substantially continuously flat depositing surface for depositing the material layers (ML); ii) depositing the at least one material layer (ML) on the common, substantially continuously flat deposit surface; iii) lowering the first plate (200) by the lifting device (500) during or after the depositing of the individual material layer (ML) by a distance corresponding to a thickness of an individual material layer (ML); iv) pressing the uppermost material layer (ML) located on the first plate (200) by means of the clamping fingers (310) against the first plate (200) or the layer stack (LS) located thereon; v) moving the at least one first sub-section (210) and the at least one second sub-section (220) into a second orientation in which the at least one first sub-section (210) and the at least one second sub-section (220) form a free space (240) between the first storage surface (211) and the second storage surface (221) for removing the layer stack (LS) from the stacking unit (100); vi) inserting removal fingers (250) into the free space (240) between the first storage surface (211) and the second storage surface (221); vii) Removing the layer stack (LS) from the stacking unit (100) by the removal fingers (250).

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