Electrode tab manufacturing equipment

Abstract

The present invention provides electrode tab manufacturing equipment that can produce electrode tabs on which a conductive polymer film is uniformly formed on the surface, thereby improving the electrical performance of the electrode tabs. [Solution] In the electrode tab manufacturing machine 100, the feeding device 10 is used for the continuous feeding of aluminum foil. The impregnation and penetration device 20 includes a multi-stage impregnation and penetration unit 21 and a dryer 214. Each stage of the impregnation and penetration unit includes an impregnation tank 211 containing a conductive polymer solution and a group of liquid replenishment rollers provided within the impregnation tank. The aluminum foil is transported immersed in the conductive polymer solution by bypassing the bottoms of two liquid replenishment rollers 212 in the liquid replenishment roller group. The liquid level of the conductive polymer solution does not exceed the central axis of the liquid replenishment rollers, and the rotation direction of the liquid replenishment rollers is opposite to the driving direction due to the action of the aluminum foil on the liquid replenishment rollers. The cutting and winding device 30 cuts and winds the aluminum foil into electrode tabs of a predetermined size.

Description

Technical Field

[0001] This application relates to the technical field of capacitors, and particularly to electrode tab manufacturing equipment.

Background Art

[0002] The electrolyte of a polymer organic semiconductor aluminum solid electrolytic capacitor, that is, an organic semiconductor (Organic semi - conductor, OS - CON) capacitor, uses a polymer material with higher conductivity than the electrolyte of a conventional aluminum electrolytic capacitor (which can reach a highly conductive state through doping and its conductivity can reach 1000 S / cm or more).

[0003] In the conventional process, after the production of the capacitor core wrap is completed, conductive polymer impregnation is carried out to form a conductive polymer film on the surfaces of the positive and negative electrode sheets. However, the capacitor core wrap has a certain thickness and length of the winding layer. In the process of nailing the core wrap, a certain winding tightness is required when wrapping the electrode material and the separator. Moreover, in the conventional impregnation technology, after covering with a rubber cover first and then impregnating, since the rubber cover is adhered to the top of the core wrap, during impregnation, the conductive polymer material only gradually penetrates into the micro - gaps of the electrode material layer from the pinholes at the bottom of the core wrap and the electrolytic paper in the outer layer of the core wrap. As a result, for a capacitor core wrap with a large diameter, the impregnation effect of its electrode tab is poor and it is difficult to penetrate the entire capacitor core wrap. Due to this impregnation non - permeation phenomenon, the impregnation on the surfaces of the positive and negative electrode tabs becomes non - uniform, and the produced capacitor has an increased internal resistance, a decreased capacitance, and deteriorated electrical performance.

Summary of the Invention

Problems to be Solved by the Invention

[0004] This application provides electrode tab manufacturing equipment to solve the problems in the prior art that the impregnation and penetration effect of the conductive polymer material into the electrode tab is not good, the quality of the produced product is not high, and the performance deteriorates.

Means for Solving the Problems

[0005] To achieve the above objective, this application provides an electrode tab manufacturing apparatus comprising a feeding device, an impregnation device, and a cutting and winding device arranged in order along the transport direction of aluminum foil, wherein the feeding device is used to feed out the aluminum foil, the impregnation device is used to form a conductive polymer film on the surface of the fed-out aluminum foil, and the cutting and winding device then cuts and winds the aluminum foil into electrode tabs of a predetermined size. The impregnation and penetration apparatus comprises a multi-stage impregnation and penetration unit, each stage of the impregnation and penetration unit comprising an impregnation tank containing a conductive polymer solution and a group of liquid replenishment rollers provided within the impregnation tank, the group of liquid replenishment rollers comprising two horizontally provided liquid replenishment rollers, the aluminum foil being transported immersed in the conductive polymer solution by bypassing the bottoms of the two liquid replenishment rollers, the liquid level of the conductive polymer solution not exceeding the central axis of the liquid replenishment rollers, and the rotation direction of the liquid replenishment rollers being opposite to the driving direction due to the action of the aluminum foil on the liquid replenishment rollers.

[0006] In some embodiments, the liquid replenishment roller has a diameter that does not exceed the depth of the impregnation tank and is not less than two-thirds of the depth of the impregnation tank, and its top does not extend beyond the opening of the impregnation tank, depending on the installation position of the liquid replenishment roller in the impregnation tank.

[0007] In some embodiments, the fluid replenishment roller group in each stage of the impregnation penetration unit is driven synchronously. Each of the fluid replenishment rollers in the fluid replenishment roller group extends to the outside of the impregnation tank and is connected to a drive member via a timing belt, and the fluid replenishment rollers are synchronously driven to rotate via the drive member.

[0008] In some embodiments, each stage of the impregnation penetration unit further includes a group of adjustment rollers provided above the impregnation tank for adjusting the thickness of the conductive polymer solution on the surface of the aluminum foil.

[0009] In some embodiments, the group of adjustment rollers includes a first adjustment roller and a second adjustment roller that are offset vertically, the second adjustment roller being fixedly mounted, and the first adjustment roller being movable laterally, and the aluminum foil being conveyed in an "S" shape between the first adjustment roller and the second adjustment roller. The closest distance between the first adjustment roller and the second adjustment roller is not less than the thickness of the aluminum foil.

[0010] In some embodiments, each stage of the impregnation penetration unit further includes a dryer for drying the aluminum foil that has passed through the group of adjustment rollers, each of which is connected to a corresponding group of adjustment rollers. Each of the aforementioned dryers is provided independently, and its drying temperature can be adjusted independently.

[0011] In some embodiments, the dryer includes a plurality of dryers arranged sequentially away from the group of adjustment rollers, and the drying temperature provided by each dryer tends to decrease in the direction away from the group of adjustment rollers.

[0012] In some embodiments, the impregnation and penetration apparatus further includes a pretreatment unit for surface treatment of the aluminum foil, wherein the aluminum foil passes through the pretreatment unit and then enters the impregnation and penetration unit, the pretreatment unit The apparatus includes a pretreatment tank containing a cleaning and modifying solution, and a guide roller provided within the pretreatment tank, wherein the aluminum foil is transported by immersion in the cleaning and modifying solution, and is bypassed via the bottom of the guide roller.

[0013] In some embodiments, the feeding device, the impregnation and penetration device, and the cutting and winding device are provided with a plurality of straight rollers, which are used to guide the aluminum foil in the transport direction and transport it between the feeding device and the cutting and winding device.

[0014] In some embodiments, the cutting and winding device controls the feeding speed of the feeding device, and the feeding device includes a magnetic powder brake, which controls the tension stability of the aluminum foil during transport.

[0015] The present invention proposes an electrode tab manufacturing apparatus. The electrode tab manufacturing apparatus includes a feeding device, an impregnation device, and a cutting and winding device arranged in order along the aluminum foil transport direction, wherein the feeding device is used to feed out aluminum foil, the impregnation device forms a conductive polymer film on the surface of the aluminum foil, the cutting and winding device cuts the aluminum foil into electrode tabs of a predetermined size and winds it, the impregnation device includes a multi-stage impregnation unit, each stage of the impregnation unit includes an impregnation tank containing a conductive polymer solution and a group of liquid replenishment rollers provided in the impregnation tank, the group of liquid replenishment rollers includes two horizontally provided liquid replenishment rollers, the aluminum foil is transported immersed in the conductive polymer solution by bypassing the bottom of the two liquid replenishment rollers, the liquid level of the conductive polymer solution does not exceed the central axis of the liquid replenishment rollers, and the rotation direction of the liquid replenishment rollers is opposite to the driving direction due to the action of the aluminum foil on the liquid replenishment rollers. [Effects of the Invention]

[0016] The proposed technology involves the combined efforts of the above-described feeding device, impregnation device, and cutting and winding device to complete the steps of feeding aluminum foil, impregnation with a conductive polymer film solution, and cutting and winding aluminum foil. Each stage of the impregnation and penetration unit, with the above configuration, can transport the aluminum foil a certain distance so as to immerse it in the conductive polymer solution, thereby achieving double-sided penetration of the aluminum foil. In particular, by designing the liquid level of the conductive polymer solution not to exceed the central axis of the liquid replenishment roller, and the rotation direction of the liquid replenishment roller to be opposite to the driving direction due to the action of the aluminum foil on the liquid replenishment roller, the amount of conductive polymer used is reduced, thereby lowering costs. Furthermore, the liquid replenishment roller rotates to replenish the conductive polymer solution in the angle formed with the aluminum foil, and can replenish the conductive polymer solution on the side of the aluminum foil closer to the liquid replenishment roller. In addition, it ensures that the amount of conductive polymer solution on both sides of the aluminum foil is the same, thereby ensuring that the conductive polymer film formed on both sides of the aluminum foil is uniform and of equal thickness, improving the electrical performance parameters of the manufactured electrode tab. [Brief explanation of the drawing]

[0017] To more clearly illustrate the embodiments of this application or the technical concepts in the prior art, the drawings that may be used in the description of the embodiments or the prior art are briefly described below. Clearly, the drawings in the following description are only a few embodiments of this application, and those skilled in the art can obtain other drawings based on these without any creative effort. [Figure 1] This is a schematic diagram of the configuration of an electrode tab manufacturing apparatus in one embodiment of this application. [Figure 2] This is a schematic diagram of the synchronous drive configuration of the fluid supply roller in one embodiment of this application. [Figure 3] This is a schematic diagram of the transport of aluminum foil in a group of adjustment rollers in one embodiment of this application. [Figure 4] This is a schematic diagram of the modularization of a dryer in one embodiment of this application. [Modes for carrying out the invention]

[0018] The following will clearly and completely describe the technical solutions of the embodiments of the present application in connection with the drawings of the embodiments of the present application. Obviously, the described embodiments are only some embodiments of the present application, not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor belong to the protection scope of the present application.

[0019] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present application are only used to explain the relative positional relationship and movement status between components in a specific posture (as shown in the drawings). When the specific posture changes, the directional indications will also change accordingly.

[0020] Furthermore, when an element is referred to as being "fixed to" or "installed on" another element, it may be directly located on the other element or there may be a central element present at the same time. When an element is referred to as being "connected to" another element, it may be directly connected to the other element or there may be a central element present at the same time.

[0021] Also, the descriptions regarding "first", "second", etc. in this specification are only for the purpose of explanation, and it is impossible to understand that they indicate or imply relative importance or implicitly indicate the number of the indicated technical features. Therefore, the features defined by "first" and "second" can include at least one feature explicitly or implicitly. In addition, the technical solutions between the embodiments can be combined with each other, but it must be based on what can be realized by those skilled in the art. If contradictions or impossibilities occur in the combination of technical solutions, such combinations of technical solutions do not exist and are considered not to be within the protection scope required by the present application. [[ID=!17]]

[0022] As shown in FIG. 1, the present application proposes an electrode tab manufacturing apparatus 100 with characteristics of high integration and automation to efficiently and accurately produce electrode tabs, and the produced electrode tabs have high conductivity.

[0023] Specifically, the electrode tab manufacturing equipment 100 includes a feeding device 10, an impregnation penetration device 20, and a cutting and winding device 30, which are provided in sequence along the transport direction of the aluminum foil. The feeding device 10 is at the starting part of the electrode tab manufacturing equipment 100 and is used for continuous feeding of the aluminum foil. In a specific configuration, it is equipped with an accurate tension control system such as a magnetic powder brake to ensure that the aluminum foil maintains a certain tension during feeding, avoiding the influence of the transport instability of the aluminum foil caused by excessive tightening or loosening on the subsequent processing of the aluminum foil. The impregnation penetration device 20 is an important part of the electrode tab manufacturing equipment 100 and is used to form a uniform conductive polymer film on the surface of the aluminum foil, thereby improving the electrical performance of the electrode tab by the conductive polymer film. The cutting and winding device 30 is at the last part of the electrode tab manufacturing equipment 100 and is used to cut and wind the aluminum foil processed by the impregnation penetration device 20 into electrode tabs of a predetermined size, facilitating the subsequent manufacturing of capacitors.

[0024] The aluminum foil cutting and winding device is composed of parts such as a cutting unit, a winding unit, and a control system. These parts can realize the continuous transport, accurate cutting, and orderly winding of the aluminum foil through mechanical transmission and electrical control. In a further solution, a sensor and an encoder for detecting the transport speed and position of the aluminum foil in real time are installed in the winding unit. A programmable logic device is adopted as the central controller, and based on the feedback signals of the sensor and the encoder, the operations of the cutting unit and the winding unit can be accurately controlled. In addition, a tension sensor and a tension controller are provided in the winding unit to automatically adjust the winding speed and tension according to the tension change of the aluminum foil, maintaining the flatness and tightness of the aluminum foil.

[0025] To achieve synchronization between cutting and winding, parameters such as cutting width and winding speed are pre-set via a central controller to ensure that cutting and winding are performed at a predetermined rhythm. During the cutting process, the central controller adjusts the blade rotation speed to suit the real-time transport speed and position of the aluminum foil. In one specific configuration, the cutting unit employs a high-precision cutting blade to ensure that the cut edges of the aluminum foil are flat and burr-free, and the winding unit employs an air shaft or a mechanically locked winding roller to ensure that the aluminum foil is wound tightly and orderly onto the roller.

[0026] Furthermore, in the transport process of the aluminum foil feeding device 10, impregnation device 20, and cutting and winding device 30, multiple guide rollers 210 are provided. These multiple guide rollers 210 are mainly used to guide the transport direction of the aluminum foil, ensuring that the aluminum foil can smoothly pass through each processing stage along a predetermined path. To avoid scratching or damaging the aluminum foil, soft or smooth-surfaced guide rollers 210 can be selected and used.

[0027] Electrode tabs manufactured with the apparatus of this application can uniformly form a conductive polymer film on the electrode surface, providing additional electron transport paths through the conductive polymer film, ensuring uniform electron distribution and high-speed transport on the electrode surface, enhancing the conductivity of the electrode, and thereby achieving improved performance of the electrode tabs before core wrapping.

[0028] As shown in Figure 1, the impregnation and penetration apparatus 20 includes a multi-stage impregnation and penetration unit 21, each stage of the impregnation and penetration unit 21 including an impregnation tank 211 containing a conductive polymer solution and a group of liquid replenishment rollers provided within the impregnation tank 211, the group of liquid replenishment rollers including two horizontally provided liquid replenishment rollers 212, the aluminum foil bypassing the bottom of the two liquid replenishment rollers 212 so as to be transported immersed in the conductive polymer solution, the liquid level of the conductive polymer not exceeding the central axis of the liquid replenishment rollers 212, and the rotation direction of the liquid replenishment rollers 212 opposite to the driving direction due to the action of the aluminum foil on the liquid replenishment rollers 212.

[0029] In this embodiment, as the aluminum foil passes through the impregnation device 20, it sequentially passes through the multi-stage impregnation unit 21, thereby ensuring that the conductive polymer solution sufficiently forms a conductive polymer film on the aluminum foil and improving the electrical properties of the electrode tab.

[0030] To understand this, the aluminum foil can be transported a certain distance so as to bypass the bottom of the two fluid rollers 212, under the limit guide action of the two fluid rollers 212, that it is completely immersed in the conductive polymer solution, and both sides of the aluminum foil can be simultaneously penetrated by the conductive polymer solution, the distance being the distance between the two fluid rollers 212.

[0031] However, when the aluminum foil is discharged from the impregnation tank 211, it is transported in close contact with the liquid replenishment roller 212. At this time, under the extrusion action of the liquid replenishment roller 212, the conductive polymer solution on the side of the aluminum foil closest to the liquid replenishment roller 212 becomes less than the conductive polymer solution on the side away from the liquid replenishment roller 212, resulting in an uneven distribution of the conductive polymer solution on both sides of the aluminum foil. Therefore, the rotation direction of the liquid replenishment roller 212 is further reversed to the direction of driving due to the action of the aluminum foil on the liquid replenishment roller 212. In this way, when the liquid replenishment roller 212 rotates in the reverse direction, the liquid replenishment roller 212 can move a portion of the conductive polymer solution along its surface, thereby transferring a portion of the conductive polymer solution into the narrow angle between the liquid replenishment roller 212 and the aluminum foil, and thereby replenishing the liquid on the side of the aluminum foil closest to the liquid replenishment roller 212. For example, if the aluminum foil in this application moves along a roughly right-to-left path, the liquid replenishment roller 212 that actually replenishes the liquid is one located towards the left side, and performs its liquid replenishment function when the aluminum foil is discharged from the impregnation tank 211.

[0032] The percentage composition of the conductive polymer solution is mainly 85-95% poly-3,4-ethylenedioxythiophene / 3,4-ethylenedioxythiophene monomer, 5-10% polyglycerin, 1-5% ethylene glycol, 0.1-0.5% surfactant, 0.1-3% pressure improver, 0.1-1% alkyl sulfonic acid, and 0.1-2.5% aqueous ammonia. Because the conductive polymer solution is expensive, in order to save costs and minimize its use in actual application processes, the liquid level of the conductive polymer does not exceed the central axis of the liquid replenishment roller 212, and the configuration is designed so that liquid replenishment is performed by the liquid replenishment roller 212.

[0033] In some embodiments, the liquid replenishment roller 212 has a diameter that does not exceed the depth of the impregnation tank 211 and is not less than two-thirds of the depth of the impregnation tank 211, and its top does not extend beyond the opening of the impregnation tank 211, depending on the installation position of the liquid replenishment roller 212 in the impregnation tank 211.

[0034] In this embodiment, the size and volume of the liquid replenishment roller 212 are set. If the diameter of the liquid replenishment roller 212 is too large, it is prevented from contacting the bottom of the tank, or if the top of the liquid replenishment roller 212 exceeds the tank opening, the solution will spill out of the impregnation groove 211 during the process of moving the conductive polymer solution along its surface, thus preventing waste of the solution. In addition, in order to reduce the problem of bending damage to the aluminum foil material caused by the diameter of the liquid replenishment roller 212 being too small, the outer diameter of the liquid replenishment roller 212 must be designed to be sufficiently large. Furthermore, in order to reduce damage to the aluminum foil, the surface of the liquid replenishment roller 212 is treated to exhibit a smooth "mirror surface".

[0035] As shown in Figure 2, in some embodiments, the fluid replenishment rollers in each stage of the impregnation penetration unit 21 are driven synchronously, and the fluid replenishment rollers 212 in each fluid replenishment roller group extend to the outside of the impregnation tank 211 and are connected to a drive member 24 via a timing belt 23, which synchronously drives the fluid replenishment rollers 212 to rotate by the drive member.

[0036] In this embodiment, the fluid rollers 212 in each fluid roller group extend to the outside of the impregnation tank 211 and are connected to the drive member 24 via a timing belt 23. In this way, when the drive member 24 is activated, the timing belt 23 causes all the fluid rollers 212 to rotate synchronously, ensuring stability and consistency in the impregnation and penetration process of the aluminum foil, improving production efficiency, and allowing the aluminum foil to maintain uniform tension and speed during the immersion and transport processes, thereby ensuring the product quality of the electrode tabs.

[0037] The drive member 24 uses a servo motor or a stepping motor to ensure the rotational speed of the fluid supply roller 212 and to provide the necessary torque.

[0038] As shown in Figure 1, in some embodiments, each stage of the impregnation and penetration unit 21 further includes a group of adjustment rollers 213 provided above the impregnation tank 211 for adjusting the thickness of the conductive polymer solution on the surface of the aluminum foil.

[0039] In this embodiment, the adjustment roller group 213 is provided above the impregnation tank 211, so that the thickness of the aluminum foil can be adjusted by the adjustment roller group 213 immediately after it leaves the impregnation tank 211, ensuring a continuous process flow of the aluminum foil during the impregnation and adjustment process and improving production efficiency. By precisely controlling the parameters of the adjustment roller group 213, a uniform and stable conductive film can be obtained, thereby improving the quality and performance of the electrode tabs.

[0040] As shown in Figures 1 and 3, in some embodiments, the adjustment roller group 213 includes a first adjustment roller 2131 and a second adjustment roller 2132 that are offset vertically, the second adjustment roller 2132 being fixed, and the first adjustment roller 2131 being movable laterally, and the aluminum foil is conveyed in an "S" shape between the first adjustment roller 2131 and the second adjustment roller 2132. The closest distance between the first adjustment roller 2131 and the second adjustment roller 2132 is not less than the thickness of the aluminum foil.

[0041] In this embodiment, the second adjustment roller 2132 is fixedly provided to the aluminum foil, offering a stable support surface, and works in cooperation with the first adjustment roller 2131 to jointly complete the adjustment of the thickness of the conductive polymer solution on the aluminum foil. The first adjustment roller 2131 is movable laterally, thereby allowing its position to be adjusted as needed, changing the gap between it and the second adjustment roller 2132, and further adjusting the thickness of the conductive polymer solution on the aluminum foil. Because the aluminum foil is transported in an "S" shape, it is subjected to pressure from different directions as it passes through the group of adjustment rollers 213, and these pressures work together to ensure that the conductive polymer solution is distributed more uniformly across the surface of the aluminum foil.

[0042] Of particular note is that the closest distance between the first adjustment roller 2131 and the second adjustment roller 2132 is not less than the thickness of the aluminum foil, thereby ensuring that the aluminum foil can pass smoothly through the adjustment roller group 213 without being damaged due to a gap that is too small.

[0043] As shown in Figure 1, in some embodiments, each stage of the impregnation and penetration unit 21 is connected to a corresponding group of adjustment rollers 213, and further includes a dryer 214 for drying the aluminum foil that has passed through the group of adjustment rollers 213, each dryer 214 being independently provided and capable of controlling its drying temperature independently.

[0044] In this embodiment, the main role of the dryer 214 is to dry the aluminum foil that has passed through the adjustment roller group 213, remove excess conductive polymer solution and moisture from the surface of the aluminum foil, and form a uniform and stable conductive film.

[0045] Each dryer 214 is connected to a corresponding adjustment roller group 213, and similarly, the aluminum foil enters the dryer 214 for drying immediately after its film thickness has been adjusted by the adjustment roller group 213, thereby ensuring that the aluminum foil can maintain a continuous process flow during the impregnation, adjustment, and drying processes.

[0046] In a further design proposal, each dryer 214 is provided independently, allowing its drying temperature to be adjusted independently, optimizing the aluminum foil drying process and avoiding issues with film quality due to overheating or overcooling. This improves the flexibility and stability of the system.

[0047] In a further configuration, the dryer 214 includes a plurality of dryers 214 arranged sequentially away from the adjustment roller group 213, and the drying temperature provided by each dryer 214 tends to decrease in the direction away from the adjustment roller group 213.

[0048] To make it clear, the purpose of this temperature gradient design is to optimize the drying process, which occurs immediately after the aluminum foil is discharged from the impregnation device and passes through the adjustment roller group 213, when the conductive polymer film on its surface may still contain more solvent or may not be fully cured. Therefore, high temperatures are necessary to accelerate the volatilization of the solvent and the curing process of the film. However, as the aluminum foil continues to advance, the conductive polymer film on its surface gradually stabilizes, and at this point, the drying temperature needs to be lowered to avoid problems such as a decrease in film performance due to excessive heating or deformation of the aluminum foil.

[0049] As shown in Figure 4, in one specific configuration, each dryer 214 includes an infrared drying unit 2142, a humidity sensor 2141, a humidity control module 2140, and a mobile module 2143. The infrared drying unit 2142 is mounted on the mobile module 2143 to move closer to or further away from the surface of the aluminum foil under the drive of the mobile module 2143. The humidity sensor 2141 is used to detect the humidity of the surface of the aluminum foil that has passed through and to feed back the humidity data to the humidity control module 2140. Normally, when the aluminum foil enters the dryer 214, the humidity of the conductive polymer on its surface is detected, and after analysis by the humidity control module 2140, temperature control is achieved by adjusting the power of the infrared drying unit 2142 or controlling the movement of the mobile module 2143 to adjust the relative distance between the infrared drying unit 2142 and the surface of the aluminum foil. The aluminum foil achieves a constant drying process when it is discharged from the dryer 214.

[0050] Specifically, the infrared drying unit 2142 achieves the drying objective by heating the conductive polymer film on the surface of the aluminum foil by emitting infrared rays. Infrared rays have characteristics such as strong penetration power, fast heating speed, and high thermal efficiency, which can rapidly increase the surface temperature of the aluminum foil while reducing energy consumption. The humidity sensor 2141 detects the humidity on the surface of the aluminum foil in real time, converts the humidity data into an electrical signal or other identifiable format, and feeds the detected humidity data back to the humidity control module 2140, providing a policy basis for the control system and ensuring the accuracy and stability of the drying process. The humidity control module 2140 receives the data transmitted from the humidity sensor 2141, performs analysis processing, and determines the current humidity state of the conductive polymer film on the surface of the aluminum foil. Based on the analysis results, it adjusts the relative distance between the infrared drying unit 2142 and the surface of the aluminum foil by adjusting the power of the infrared drying unit 2142 or controlling the movement of the movement module 2143, thereby controlling the drying speed and degree of dryness of the aluminum foil.

[0051] To make it clear, the humidity sensor 2141 in this embodiment employs a non-contact measurement principle, thereby avoiding physical damage to the conductive polymer film on the surface of the aluminum foil that is not completely dry, and ensuring accurate and real-time measurement. The humidity control module 2140 further includes a preset humidity threshold setting unit, which allows the user to customize the humidity threshold based on the material, thickness, and required dryness of the conductive polymer film on the surface of the aluminum foil, and automatically adjusts the power or position of the infrared drying unit 2142 based on the comparison result of real-time humidity data with the preset threshold.

[0052] Furthermore, the infrared drying unit 2142 employs multi-band infrared radiation technology. The humidity control module 2140 can intelligently select the optimal infrared band for heating according to changes in the humidity of the aluminum foil surface, improving drying efficiency and uniformity.

[0053] In some embodiments, the moving module 2143 includes a precise transmission mechanism and a position feedback sensor to ensure accuracy and stability during movement of the infrared drying unit 2142, and the position feedback sensor feeds back real-time position information to the humidity control module 2140 to achieve closed-loop control.

[0054] In this embodiment, the transmission mechanism is designed using high-precision, low-friction materials and assemblies to reduce vibration and deviation during movement and ensure stable operation of the infrared drying unit 2142. The materials may be selected to have high hardness, wear resistance, and low thermal expansion and adsorption properties, ensuring that the transmission components are less prone to wear during long periods of motion, maintaining high-precision gear ratios and transmission efficiency, and reducing size changes due to temperature changes, thereby ensuring the stability and precision of the transmission mechanism. Some components may employ rolling friction assemblies such as rolling bearings and ball screws to reduce frictional resistance and vibration, and lubricants or self-lubricating materials, such as polytetrafluoroethylene, may be used between transmission members to reduce friction and adsorption, thereby reducing wear and vibration.

[0055] In some embodiments, the humidity control module 2140 further includes a fault alert module that monitors the operating status of the humidity sensor 2141, the infrared drying unit 2142, and the mobile module 2143 in real time, and can immediately issue an alert signal if an anomaly is detected, thereby activating alternative measures to ensure the continuous operation of the production line. In further configurations, the temperature control system further includes a remote monitoring interface that allows operators to remotely monitor the drying process, adjust parameters, and view historical data and alarm information via terminal devices such as computers and mobile phones while away from the production line.

[0056] In a further configuration, since there are conductive polymer layers on both sides of the aluminum foil, two sets of infrared drying units 2142 may be provided on each side to ensure the synchronization of the drying process of the conductive polymer films on both sides of the aluminum foil. The two sets of infrared drying units 2142 are positioned opposite each other on the relative sides of the aluminum foil, and each is connected to a corresponding mobile module 2143. Furthermore, the humidity control module 2140 in each controller can control the drying processes on both sides at the same or different frequencies based on the humidity of the conductive polymer film layers on both sides.

[0057] Overall, this application provides a configuration in which multiple dryers 214 are provided sequentially, i.e., multiple drying sections are provided along the aluminum foil transport direction. Exemplarily, this includes a first drying section, a second drying section, and a third drying section provided sequentially, starting close to and then moving away from the adjustment roller group 213. The first drying section is used to provide a first drying temperature, the second drying section is used to provide a second drying temperature, and the third drying section is used to provide a third drying temperature, the third drying temperature not exceeding the second drying temperature, and the second drying temperature not exceeding the first drying temperature. The second drying section is located after the first drying section and provides a lower second drying temperature, further drying the aluminum foil at this stage while simultaneously avoiding damage to the aluminum foil or conductive polymer film due to excessively high temperatures. The third drying section is provided at a distance from the adjustment roller group 213 and provides the lowest third drying temperature. The objective of this stage is to ensure complete drying of the aluminum foil and to maintain the stability and performance of the conductive polymer film. For example, the temperature range for the first drying temperature is 125-150°C, the temperature range for the second drying temperature is 105-125°C, and the temperature range for the third drying temperature is 85-105°C. Adopting this stepped temperature control policy helps avoid problems such as cracking, deformation, or performance degradation of the aluminum foil due to excessively high temperatures during drying.

[0058] In some embodiments, the impregnation and penetration apparatus 20 further includes a pretreatment unit 22 for surface treatment of aluminum foil, and the aluminum foil, after passing through the pretreatment unit 22, enters the impregnation and penetration unit 21, the pretreatment unit 22 includes a pretreatment tank 221 containing a cleaning and modification solution, and guide rollers 222 provided within the pretreatment tank 221, and the aluminum foil bypasses the bottom of the guide rollers 222 so that it is transported immersed in the cleaning and modification solution.

[0059] In this embodiment, as the aluminum foil passes through the pre-treatment unit 22, it bypasses the bottom of the guide roller 222 and is immersed in the cleaning and modification solution. In the solution, oil stains and impurities are removed from the surface of the aluminum foil, and the surface of the aluminum foil is modified, improving its permeability and adhesion. After treatment, the aluminum foil maintains its original transport direction and enters the subsequent impregnation and penetration unit 21, where it adsorbs the conductive polymer solution more uniformly and forms a higher quality conductive film.

[0060] The pretreatment solution is another cleaning and modifying solution, such as an aqueous liquid containing a silicon alkane. In a specific configuration, the guide roller 222 in the pretreatment unit 22 may also have a configuration similar to that of the liquid replenishment roller group, so that the aluminum foil can be transported a certain distance in the cleaning and modifying solution in the pretreatment tank 221, and is driven synchronously by a drive member unified with that of the liquid replenishment roller group. Furthermore, a group of adjustment rollers 213 and a dryer 214 may be provided to guide and adjust the transport direction of the aluminum foil and realize the drying operation. The group of adjustment rollers 213 and the dryer 214 may both use the configuration of the impregnation and penetration unit 21 described above.

[0061] Furthermore, in the capacitor manufacturing process, the process manufacturing steps can be set up based on the electrode tabs manufactured in this application. For example, the innovative process manufacturing step setting in this application integrates the electrode tab manufacturing - core wrapping nailing - electrolyte impregnation - assembly - aging test steps into a single machine. Such an innovative process proposed based on the electrode tabs produced in this application not only ensures product quality but also reduces the number of processing steps, shortens the production line length, and saves costs. Moreover, it thoroughly solves the technical deficiency of insufficient impregnation of solid and liquid-solid two-phase products in conventional process manufacturing steps. Such products are no longer limited by the size of the capacitor product, and capacitors of any size can be manufactured as needed. They have superior electrical performance and a wider range of applications, such as in automotive and military industries, where a wide temperature range, high specific volume, and long lifespan are required.

[0062] In one specific analysis, solid-liquid two-phase capacitor products with parameters of 450V and 330μF were manufactured based on the electrode tab manufacturing process of this application and a conventional impregnation process, and their electrical performance parameters were tested and compared at room temperature and low temperature. The test results are shown in Tables 1 and 2, respectively.

[0063] Table 1: Test data of solid-liquid two-phase capacitors manufactured using the electrode tabs of the present invention. JPEG2026137633000002.jpg46170

[0064] Table 2: Test data for solid-liquid two-phase capacitors manufactured using a conventional impregnation process. JPEG2026137633000003.jpg46170

[0065] As can be seen from Tables 1 and 2, at 20°C, the average capacitance of the solid-liquid two-phase capacitor manufactured using the electrode tabs of the present invention was 319 μF, approximately 97% of the rated capacitance, and the capacitance loss was only 3%. This indicates that the manufacturing method of the electrode tabs of the present invention can fully meet the product standard requirements, and at -55°C, the electrical performance of the product, such as capacitance change (ΔC / C), loss (tgδ), and impedance ratio (Z-55°C / Z20°C), all meet the product standard requirements. At 20°C, the average capacitance of the solid-liquid two-phase capacitor manufactured using a conventional impregnation process was 262.2 μF, approximately 79% of the rated capacitance, and the capacitance loss reached 21%. This indicates that the conventional impregnation technology cannot meet the product standard requirements, and at -55°C, the electrical performance of the product, such as capacitance change (ΔC / C), loss (tgδ), and impedance ratio (Z-55°C / Z20°C), all do not meet the product standard requirements.

[0066] The foregoing describes only a part of or preferred embodiments of this application, and neither the text nor the drawings can limit the scope of protection of this application. Equivalent structural transformations utilizing the contents of this specification and drawings, or their direct or indirect application to other related technical fields, under a concept integrated with this application, are included within the scope of protection of this application.

Claims

1. Electrode tab manufacturing equipment, The system includes a feeding device, an impregnation device, and a cutting and winding device, arranged in order along the transport direction of the aluminum foil, wherein the feeding device is used to feed out the aluminum foil, the impregnation device is used to form a conductive polymer film on the surface of the fed-out aluminum foil, and the cutting and winding device then cuts the aluminum foil into electrode tabs of a predetermined size and winds them up. The impregnation and penetration apparatus comprises a multi-stage impregnation and penetration unit, each stage of the impregnation and penetration unit comprising an impregnation tank containing a conductive polymer solution and a group of liquid replenishment rollers provided within the impregnation tank, the group of liquid replenishment rollers comprising two horizontally provided liquid replenishment rollers, the aluminum foil being transported immersed in the conductive polymer solution by bypassing the bottoms of the two liquid replenishment rollers, the liquid level of the conductive polymer solution not exceeding the central axis of the liquid replenishment rollers, and the rotation direction of the liquid replenishment rollers being opposite to the driving direction due to the action of the aluminum foil on the liquid replenishment rollers, characterized in that it is an electrode tab manufacturing apparatus.

2. The electrode tab manufacturing apparatus according to claim 1, characterized in that the liquid replenishment roller has a diameter that does not exceed the depth of the impregnation tank and is not less than two-thirds of the depth of the impregnation tank, and the installation position of the liquid replenishment roller in the impregnation tank ensures that its top does not exceed the opening of the impregnation tank.

3. The liquid replenishment roller group in each stage of the impregnation penetration unit is driven synchronously. The electrode tab manufacturing apparatus according to claim 2, characterized in that the fluid replacement rollers in each fluid replacement roller group extend to the outside of the impregnation tank, are connected to a drive member via a timing belt, and the fluid replacement rollers are synchronously driven to rotate via the drive member.

4. Each stage of the impregnation and penetration unit is The electrode tab manufacturing apparatus according to claim 1, further comprising a group of adjustment rollers provided above the impregnation tank for adjusting the thickness of the conductive polymer solution on the surface of the aluminum foil.

5. The adjustment roller group includes a first adjustment roller and a second adjustment roller that are offset vertically from each other, the second adjustment roller is fixedly mounted, and the first adjustment roller is movable laterally, and the aluminum foil is conveyed in an "S" shape between the first adjustment roller and the second adjustment roller. The electrode tab manufacturing apparatus according to claim 4, characterized in that the closest distance between the first adjustment roller and the second adjustment roller is not less than the thickness of the aluminum foil.

6. Each stage of the impregnation and penetration unit is Each of the corresponding adjustment roller groups is connected to a dryer for drying the aluminum foil that has passed through the adjustment roller group, The electrode tab manufacturing apparatus according to claim 4, characterized in that each of the aforementioned dryers is provided independently and its drying temperature can be adjusted independently.

7. The electrode tab manufacturing apparatus according to claim 6, wherein the dryer includes a plurality of dryers arranged sequentially in a direction away from the group of adjustment rollers, and the drying temperature provided by each dryer tends to decrease in the direction away from the group of adjustment rollers.

8. The impregnation and penetration apparatus further includes a pretreatment unit for surface treatment of the aluminum foil, and the aluminum foil, after passing through the pretreatment unit, enters the impregnation and penetration unit. The aforementioned pre-processing unit is The electrode tab manufacturing apparatus according to claim 1, comprising a pretreatment tank containing a cleaning and modifying solution, and a guide roller provided in the pretreatment tank, wherein the aluminum foil is transported by immersion in the cleaning and modifying solution, and is bypassed via the bottom of the guide roller.

9. The electrode tab manufacturing apparatus according to claim 1, characterized in that the feeding device, the impregnation and penetration device, and the cutting and winding device are provided with a plurality of straight rollers, and the plurality of straight rollers are used to guide the conveying direction of the aluminum foil and to transport it between the feeding device and the cutting and winding device.

10. The electrode tab manufacturing apparatus according to claim 1, characterized in that the cutting and winding device controls the feeding speed of the feeding device, and the feeding device includes a magnetic powder brake, the magnetic powder brake controls the tension stability of the aluminum foil during transport.

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