Adhesive-Patch Electrode Web Joining for Automated Coil Changes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The process of changing electrode webs in electrochemical cell production is time-consuming and requires human intervention, leading to machine stoppages and increased waste due to the need for a larger buffer of material to maintain production continuity.
Innovation Solution
A method and apparatus for joining electrode webs using adhesive patches applied to the free ends of unwound electrode webs, facilitated by a punch mechanism to cut and apply adhesive tape efficiently, allowing for seamless integration of new electrode webs without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operations are used for coil changes, then human intervention is required for mounting and joining electrode webs, but machine stoppages occur and productivity decreases
Solution Approach 1:
The system enables self-service through automated adhesive tape application. The adhesive tape is automatically fed from a supply roll, cut to length, and applied to the electrode web ends without manual intervention. The punching mechanism automatically positions and applies adhesive patches to join the old and new electrode webs, eliminating the need for operator involvement in the coil change process.
Solution Approach 2:
The adhesive tape is pre-cut to the required length and positioned in advance of the actual joining operation. The punching mechanism is pre-configured with the correct positioning and alignment. This preliminary preparation allows the coil change to proceed rapidly without delays for manual measurement, cutting, or positioning operations.
2Productivity
If larger buffer of electrode material is used, then production continuity is maintained, but waste increases
Solution Approach 1:
The adhesive tape is pre-cut to the exact required length for joining electrode webs, eliminating unnecessary excess material. The automated cutting mechanism ensures precise length determination based on the actual joining requirement, preventing the accumulation of unused buffer material that would otherwise be wasted.
Solution Approach 2:
The adhesive tape serves as a consumable joining medium that is applied and then discarded. This disposable approach eliminates the need for reusable mechanical joining devices and allows for precise, waste-minimizing application of adhesive material only where needed at the joining points.
3Ease of manufacture
If adhesive tape is unwound and cut manually, then joining can be performed, but time consumption increases and repeatability decreases
Solution Approach 1:
The manual mechanical operations of unwinding, measuring, cutting, and positioning adhesive tape are replaced with an automated mechanical system. The adhesive tape is automatically fed from a supply roll, precisely cut by a punching mechanism, and positioned on the electrode web ends without manual handling, dramatically reducing the time required for joining preparation.
Solution Approach 2:
The adhesive tape supply system operates continuously, with the tape being fed automatically from the supply roll through the cutting and application process. This continuous operation eliminates interruptions and delays associated with manual tape preparation, maintaining steady productivity during the coil change process.
4Ease of operation
If operator supervision is required in dry room, then coil changes can be performed, but time spent in controlled environment increases
Solution Approach 1:
The entire coil change process is designed as a self-service operation that does not require operator presence. The automated adhesive tape application system, including the supply roll, cutting mechanism, and punching apparatus, operates independently without human intervention, allowing the process to be performed quickly while minimizing time spent in the controlled dry room environment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the time required for coil changes, minimizes waste, and ensures continuous production by eliminating the need for human supervision in a controlled environment, enhancing the efficiency and repeatability of the electrode web joining process.
Implementation Method 1
A method and apparatus for joining a first electrode web to a second electrode web using adhesive patches applied to the free ends of unwound electrode webs
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for joining a first electrode web to a second electrode web comprises providing a first free end (11) of a first electrode web (f1); providing a second free end (l2) of a second electrode web (f2) at the first free end (11) of the first electrode web (f1); unwinding a first adhesive tape (n1) from a first feeding coil (b1) along a first unwinding path (63), the first adhesive tape (n1) comprising an unwound first piece of adhesive tape (b1a) that is positioned between a first part (n1a) of the first adhesive tape (n1) upstream and a second part (n1b) of the first adhesive tape (n1) downstream along the first unwinding path (63); cutting away from the first piece of adhesive tape (b1a) an inner portion of the first adhesive tape (n1) separating the inner portion of the first adhesive tape (n1) from a residual edge portion (69a) of the first adhesive tape (n1) extending along the first unwinding path (63) so as to keep the first part (n1a) of the first adhesive tape (n1) in connection with the second part (n1b) of the first adhesive tape (n1), the inner portion of the first adhesive tape (n1) forming a first adhesive patch (69b); applying said first adhesive patch (69b) at both said first free end (11) and second free end (l2); winding the residual portion (69a) of the first adhesive tape (n1) on a first winder (69) positioned downstream of the first feeding coil (b1) with respect to the first unwinding path (63).