Device and method for connecting finite material webs
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Solution Overview
Problem
Existing methods for connecting finite material webs in energy cell production face challenges in achieving high-speed, efficient, and high-quality connections to form an endless web, with potential disruptions due to material overlaps and the need for large buffer storages.
Innovation Solution
A device and method utilizing negative pressure to hold and cut material webs, applying an adhesive strip, and using a ram to press the ends together, enabling a quick and automated butt-joint connection without overlap, allowing for smaller buffer storages and increased production speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If buffer storages are increased to compensate for web connection interruptions, then production continuity is improved, but production space requirements and costs increase
Solution Approach 1:
The device performs preliminary actions by pre-positioning the new web of material in the second guide section and pre-applying adhesive to the new leading end before the actual connection is needed. This preparation allows the connection to occur rapidly when the running-out web reaches the connection point, minimizing production interruption without requiring large buffer storages.
Solution Approach 2:
The connection process is designed to complete the web joining operation as quickly as possible by using a rapid application of adhesive and immediate pressing with the ram. The system rushes through the connection operation before the buffer storage is depleted, thereby maintaining production continuity without needing large buffer capacities.
2Productivity
If production speed is increased to maximize productivity, then productivity is improved, but the time available for high-quality web connection decreases
Solution Approach 1:
The adhesive is applied to the new leading end in advance while the web is still moving at high speed. This preliminary application of adhesive eliminates the need to slow down or stop the web for adhesive application, allowing the connection to be completed rapidly without compromising production speed.
Solution Approach 2:
The device maintains continuous motion of the web through the connection zone. The running-out web and new web are both conveyed continuously, and the connection operations (adhesive application and pressing) occur while the webs are in motion, eliminating idle time and maintaining continuous productive action.
3Strength
If adhesive is applied to connect webs of material, then connection strength is improved, but material overlap and increased thickness occur
Solution Approach 1:
The device extracts the adhesive application to a separate applicator that applies adhesive only to the leading end of the new web, rather than creating an overlap joint. This allows the webs to be connected with minimal material buildup, as the adhesive is applied precisely where needed without requiring one web to overlap the other.
Solution Approach 2:
Adhesive is applied locally only to the leading end of the new web of material, rather than along the entire web or creating a broad overlap zone. This localized application minimizes the area of material buildup and maintains uniform web thickness in the connected region.
4Manufacturing precision
If a static splice is produced by reducing conveying speed to zero, then connection precision is improved, but production speed is reduced
Solution Approach 1:
The device maintains continuous conveying of both the running-out web and new web through the connection zone. The adhesive application and pressing operations occur while the webs are in motion, eliminating the need to stop the conveying system. This maintains production speed while achieving precise connection through controlled adhesive application and pressing.
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
Facilitates rapid, high-quality connections between material webs, minimizing production interruptions and enabling higher conveying speeds, thus optimizing the production process for energy cells.
Implementation Method 1
a holding device (16) which is adapted to hold the new web of material (12) in the second guide section (14) by means of negative pressure
Data Source
AI summary
The invention relates to a device and a method for connecting finite webs of material for the energy cell producing industry, wherein the device comprises a holding device adapted to hold the new web of material by means of negative pressure in the second guide section, as well as a backing element and a cutting element, downstream in the conveying direction of the holding device. The backing element and the cutting element are adapted to cut the stationary new web of material to produce a new leading end of the new web of material. The device also comprises an applicator for applying an adhesive strip to the new leading end of the new web of material and a ram and a cutting device, wherein the cutting device is adapted to cut the stationary running-out web of material to produce a new trailing end of the running-out web of material. The ram is adapted to press the trailing web end of the running-out web of material onto the adhesive strip and against the applicator in order to connect the new leading end of the new web of material to the new trailing end of the running-out web of material.