Automated Lamination of Dye-Sensitized Cell Composite Film
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Solution Overview
Problem
The manual process of laminating electrodes in dye-sensitized cells results in imprecise alignment and high labor costs due to the use of a hot glue layer that diverges from its predetermined position after heating, leading to poor yield rates and increased production costs.
Innovation Solution
A composite film with a release layer, protective layer, and hot glue layer is used, where the protective layer is adhered to the hot glue layer with a low-temperature adhesion agent, and a robotic system aligns and rolls the film to apply the hot glue layer onto the electrode, ensuring precise alignment and fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual process is used to dispose adhesion agent layer and align electrodes, then flexibility in operation is maintained, but manufacturing precision and productivity deteriorate due to imprecise alignment and high labor costs
Solution Approach 1:
The patent replaces the manual mechanical alignment process with an automated vision-guided system. CCD cameras capture images of alignment marks on both the adhesion agent layer and electrode, a control unit processes these images to calculate precise positioning, and a robotic arm executes the alignment and lamination. This substitution of manual mechanical operations with automated optical-mechanical systems simultaneously improves alignment precision while maintaining operational flexibility through programmable control.
2Strength
If hot glue layer is heated to enhance stickiness, then adhesion capability is improved, but manufacturing precision deteriorates because the hot glue layer diverges from predetermined position due to movement
Solution Approach 1:
The patent performs alignment and lamination of the hot glue layer onto the electrode before heating it to enhance adhesion. The robotic arm precisely positions and bonds the hot glue layer in its initial state, and only after this precise positioning is complete is the hot glue layer heated. This preliminary action of positioning before heating prevents the hot glue layer from diverging from its predetermined position, as the positioning occurs when the material is more stable and easier to control.
3Strength
If hot glue layer is heated and softened to enhance stickiness, then adhesion capability is improved, but ease of operation deteriorates because the softened hot glue layer is hardly taken and disposed on the counter electrode
Solution Approach 1:
The patent performs all handling, positioning, and lamination operations on the hot glue layer before heating it to soften and enhance adhesion. The robotic arm picks up the hot glue layer in its unheated state, positions it precisely using vision guidance, and laminates it onto the electrode. Only after this complete handling and positioning sequence is finished is the hot glue layer heated. This eliminates the difficulty of handling softened hot glue, as all manipulation occurs when the material is in its easier-to-handle unheated state.
Solution Approach 2:
The patent replaces manual handling of the hot glue layer with an automated robotic system equipped with vacuum suction cups or similar gripping mechanisms. This mechanical substitution allows precise picking, positioning, and placement of the hot glue layer without direct human contact, making the process easier to control and more consistent, especially when combined with the preliminary action principle of heating only after positioning.
4Manufacturing precision
If automated robotic system is used to align and laminate film, then manufacturing precision and productivity are improved, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated system where a single robotic arm performs multiple operations: picking up the adhesion agent layer, positioning it using vision guidance from CCD cameras, laminating it onto the electrode, and then repeating the process for the hot glue layer. The control unit coordinates all these functions through a unified programming interface. This multi-functionality reduces the need for separate dedicated devices for each operation, thereby managing device complexity while achieving high manufacturing precision through automated vision-guided positioning.
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 method automates the lamination process, reducing labor costs, enhancing precision, and improving yield rates by preventing the hot glue layer from shifting, thus increasing production efficiency.
Implementation Method 1
providing a substrate on a loading platform, a plurality of second targets are on an upper surface of the substrate, and the loading platform heats the substrate at least to the softening temperature
Implementation Method 2
The protective layer is adhered to the hot glue layer by an adhesion agent
Data Source
AI summary
The present invention provides a method of laminating a film for a dye-sensitized cell. First, a composite film is taken by a robotic arm, in which the composite film includes a release layer, a protective layer and a hot glue layer between the release layer and the protective layer, and the release layer is removed by the robotic arm. Then, the hot glue layer is precisely attached to a substrate by a target positioning step. Next, the protective layer is removed by the robotic arm.