Battery Grid Pasting Hopper Knurled Rollers Paste Deflector
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Solution Overview
Problem
Conventional battery plate manufacturing methods, such as orifice-type and conveyor-type pasting machines, face challenges in efficiently applying lead oxide paste to both sides of battery plate grids, with issues like grid damage, jamming, and incomplete paste coverage, leading to difficulties in producing large quantities of battery plates efficiently.
Innovation Solution
A conveyor-type pasting machine with a specialized hopper featuring closely spaced knurled rollers and an angled paste deflector generates a pressurized stream of paste, allowing consistent application to both sides of the grid through a grid support sheet and paper strip, ensuring complete coverage and reducing jamming risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If orifice-type pasting machines are used to apply paste to both sides of the grid, then complete paste coverage on both sides is achieved, but grid damage and jamming occur due to particles in the paste and grid becoming jammed between steel plates
Solution Approach 1:
The pasting process is segmented into two separate operations: first applying paste to one side of the grid, then using pressure to force paste through to the opposite side. This eliminates the need for grids to pass through narrow orifices on both sides, preventing jamming while ensuring complete coverage.
Solution Approach 2:
A support sheet is introduced as an intermediary element between the paste application system and the grid. The support sheet facilitates paste application and helps force paste through the grid to the opposite side, while also preventing direct contact between the grid and potentially damaging components.
2Reliability
If conveyor-type pasting machines are used to apply paste to grids, then grid jamming and particle impact are reduced, but incomplete paste coverage occurs on the bottom side of the grid
Solution Approach 1:
The grid is supported on a support sheet before paste application, positioning it to receive paste on the top side. The support sheet then facilitates the forcing of paste through the grid to the bottom side, ensuring complete coverage without requiring the grid to contact the conveyor belt directly.
Solution Approach 2:
Instead of attempting to apply paste to the bottom side of the grid from below (traditional conveyor-type approach), the invention forces paste through the grid from the top side to the bottom side, utilizing the thickness dimension of the grid to achieve coverage on both surfaces through a single application point.
3Productivity
If traditional methods are used to apply paste to both sides of grids, then production efficiency is maintained, but the complexity of ensuring complete coverage on both sides increases
Solution Approach 1:
The application of paste to both sides of the grid is merged into a single operation. By applying paste to one side and forcing it through to the opposite side, the system achieves complete coverage on both surfaces without requiring separate pasting stations or complex multi-sided application mechanisms.
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
The solution enables efficient and complete application of lead oxide paste to both sides of battery plate grids, enhancing production rates and reducing grid damage, while maintaining the advantages of conveyor-type machines in terms of reduced jamming and paste particle impact.
Implementation Method 1
A conveyor-type pasting machine with a specialized hopper featuring closely spaced knurled rollers and an angled paste deflector generates a pressurized stream of paste
Data Source
AI summary
An apparatus and method operations are provided for battery plate fabrication, in particular for applying paste to battery plate grids. A conveyer-type pasting machine includes a conveyer belt for moving battery plate grids under a new type of paste dispensing hopper, which includes closely spaced knurled rollers and an angled paste deflector member, which cooperate to generate a pressurized stream of paste for extrusion thru the battery plate grid. The apparatus also includes a specialized grid support sheet that also enables a consistent layer of paste to be applied to both exterior sides of a manufactured battery plate grid by enabling application of paste to one side of the grid and facilitating transmission of the paste through to and past the opposite, exterior side of the grid.