Air-Held Bipolar Electrode Welding to Prevent Contamination
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Solution Overview
Problem
Existing electrode unit manufacturing methods face challenges in preventing foreign matters from adhering to electrodes during the welding process of resin members, which can lead to contamination and reduced manufacturing efficiency.
Innovation Solution
The proposed solution involves an electrode unit manufacturing device and method that uses a transport unit to suction and hold the electrode in the air, and a welding device that welds the resin member to the electrode while it is being suctioned and held, thereby preventing foreign matters from adhering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electrode is placed on a stage or pallet during welding, then the welding process can be performed, but foreign matters may adhere to the electrode
Solution Approach 1:
A resin frame is introduced as an intermediary component between the electrode and the stage/pallet. The resin frame is temporarily welded to the electrode first, then the electrode assembly (electrode + resin frame) is placed on the stage. This intermediary structure prevents direct contact between the electrode and stage, blocking foreign matters from adhering to the electrode while still allowing the welding process to proceed.
2Object-affected harmful factors
If the electrode is held in the air by suction during welding, then foreign matter adhesion is prevented, but the device complexity increases
Solution Approach 1:
The suction-based holding mechanism replaces traditional mechanical clamping or fixation systems. By using negative pressure (suction) to hold the electrode in the air during welding, the system avoids complex mechanical adjustment mechanisms while achieving stable positioning. This pneumatic approach simplifies the overall device structure compared to alternative mechanical holding methods.
3Productivity
If the electrode is transported on a stage, then the manufacturing process is simple, but foreign matters remain on the stage and contaminate subsequent electrodes
Solution Approach 1:
The system segments the electrode handling process into distinct phases: (1) holding the electrode in the air using suction during welding, (2) placing the electrode on the stage only when necessary for positioning or transfer, and (3) removing the electrode from the stage after welding. This segmentation minimizes the electrode's contact time with the stage, reducing foreign matter adhesion risk while maintaining manufacturing efficiency.
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 effectively prevents foreign matters from adhering to the electrodes during the welding process, ensuring cleaner manufacturing conditions and improved efficiency in producing electrode units.
Implementation Method 1
a transport unit configured to transport the electrode in the air while suctioning and holding the electrode
Implementation Method 2
the bipolar electrode and the resin frame are heated by a heater
Implementation Method 3
the resin frame is welded to the electrode plate of the bipolar electrode
Data Source
AI summary
An electrode unit manufacturing device 50 is an electrode unit manufacturing device for manufacturing an electrode unit 11A by welding a resin member 21B to a bipolar electrode 11 including a current collector 15, and an active material layer provided on one surface 15a and the other surface 15b of the current collector 15. The electrode unit manufacturing device includes a robot hand 30 that transports the bipolar electrode 11 in the air while suctioning and holding the bipolar electrode 11, and a welding device 40 including a welding unit 45 that welds the resin member 21B to the bipolar electrode 11 in a state of being suctioned and held in the air by the robot hand 30.