Battery Plate Separation Using Angled Work Surface

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Solution Overview

Problem

In the manufacturing of lead-acid batteries, adjacent plates often become stuck or bonded together during the drying or curing process, making it difficult for automated enveloping machines to handle them, leading to manual separation that is physically demanding and poses health risks due to lead oxide dust exposure.

Innovation Solution

An apparatus with a moveable work surface and alignment mechanism that allows for angled positioning to separate battery plates, including a loading mechanism to orient stacks and displacement mechanisms to displace plates relative to each other, reducing manual intervention and minimizing dust exposure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual plate separation is used to handle stuck plates, then the plates can be separated for processing, but the operator is exposed to lead oxide dust and risks repetitive stress injuries

Engineering Contradiction:

Improveplate separationVSAvoidlead oxide dust exposure

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

A vibration mechanism is introduced as an intermediary device between the operator and the plates. The vibration mechanism generates vibrations that propagate through the plates to break bonds and facilitate separation, eliminating the need for operators to manually manipulate the plates and thereby preventing dust exposure and repetitive stress injuries

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The manual mechanical manipulation of plates by operators is replaced with an automated vibration-based system. The vibration mechanism uses controlled mechanical vibrations to achieve plate separation that previously required manual impact and manipulation, substituting a safer automated system for the hazardous manual process

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If manual plate separation is used, then stuck plates can be separated, but the work is physically demanding and time-consuming

Engineering Contradiction:

Improveplate separationVSAvoidprocessing efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The vibration mechanism enables the plates to separate themselves through self-generated vibrations. When the vibration mechanism activates, the vibrations propagate through the plate stack, causing adjacent plates to move relative to each other and break bonds automatically, eliminating the need for operators to perform physically demanding separation work

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual mechanical separation process is replaced with an automated vibration-based separation system. The vibration mechanism quickly generates vibrations that propagate through the plates, achieving separation in seconds rather than requiring operators to manually manipulate heavy plates, thereby significantly improving processing efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If plates are impacted on a work surface to break bonds, then some bonds are broken, but lead oxide dust is released into the air

Engineering Contradiction:

Improvebond breakingVSAvoidlead oxide dust

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

Instead of impacting plates on a work surface, the vibration mechanism applies controlled mechanical vibrations directly to the plates. These vibrations cause adjacent plates to move relative to each other, breaking bonds through vibrational energy rather than impact forces, thereby preventing the release of lead oxide dust into the air

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The vibration mechanism serves as an intermediary that transfers vibrational energy to the plates without requiring direct contact or impact with a work surface. This intermediary approach breaks bonds through controlled vibrations while containing the process within a closed system, preventing dust generation

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Automates the separation of battery plates, reducing the risk of repetitive stress injuries and health hazards while efficiently handling stuck plates, enabling safer and more efficient processing.

Implementation Method 1

a work surface for receiving a stack of battery plates, the work surface being moveable between a first position in which it is angled with respect to a horizontal plane; and a second position in which it is substantially aligned with the horizontal plane such that in use, when the work surface moves between the first and second position adjacent battery plates of the stack are displaced relative to each other

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS11495823B2Apparatus for the manufacture of battery components

Publication Date: 2022.11.08 TBS ENG LTD

AI summary

An apparatus for separating battery plates includes a work surface for receiving a stack of battery plates, and an alignment mechanism for aligning the battery plates on the work surface. The work surface is movable between a first position in which it is angled with respect to a horizontal plane and a second position in which it is substantially aligned with the horizontal plane. When the work surface moves between the first and second position adjacent battery plates of the stack are displaced relative to each other.