Electrode Production Method Using Bent Attachment Portions
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Solution Overview
Problem
Existing methods for suspending rectangular plate-like electrode substrates during manufacturing, such as those used in electrolysis, face issues with substrate fall-off during heat treatment due to thermal expansion and external forces, leading to wrinkles and bulges on the electrode surface, which can damage the product and hinder productivity.
Innovation Solution
A method involving attachment portions at the ends of the electrode substrate, linearly bent to form even sides, which are inserted into a suspension jig and a lower jig, providing resistance against pulling forces and thermal deformation, thereby maintaining the substrate's flatness and preventing fall-off.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode substrate is suspended using conventional methods (suspension hole with claw or wire), then the substrate can be held during manufacturing, but the substrate may be bent, develop wrinkles and creases, or the suspension hole may be deformed or broken due to low rigidity and thermal expansion differences
Solution Approach 1:
The substrate is segmented into multiple suspension points along its length, with each point providing independent support. This distributes the suspension load and allows the substrate to maintain flatness during thermal processing without concentrating stress at single attachment points
Solution Approach 2:
A suspension rod acts as an intermediary element between the substrate and the suspension system. The rod provides mechanical support while allowing thermal expansion differences between the substrate and jig materials without transmitting deformation to the substrate surface
2Stability of the object's composition
If the substrate is restrained during suspension to prevent movement, then positioning stability is improved, but thermal deformation and wrinkles are generated during firing due to restricted thermal expansion
Solution Approach 1:
The suspension system transitions from a static restrained configuration to a dynamic configuration that adapts during thermal processing. The substrate is positioned stably during loading but is allowed to expand freely during firing, with the suspension rod accommodating dimensional changes without inducing deformation
3Manufacturing precision
If the substrate is suspended without restraint to allow thermal expansion, then thermal deformation is suppressed, but the substrate may fall or come off the jig during severe heat cycles and external forces
Solution Approach 1:
The substrate is preliminarily positioned and secured at multiple suspension points before thermal processing begins. This preliminary fixation prevents falling during handling and loading, while the suspension design allows subsequent thermal expansion without restriction during the firing process
4Reliability
If multiple suspension points are used to improve stability, then substrate retention is enhanced, but the device complexity and attachment process become more complicated
Solution Approach 1:
The suspension rod serves multiple functions simultaneously: it provides mechanical support at multiple points, allows thermal expansion, prevents substrate fall, and maintains positioning stability. This multi-functionality achieves reliable suspension without requiring a complex multi-component jig structure
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 enhances the resistance against pulling forces, reduces the occurrence of wrinkles and bulges, improves productivity, and allows for more efficient use of materials by minimizing waste and simplifying the attachment process, resulting in higher-quality electrodes with improved aesthetic and functional performance.
Implementation Method 1
each of the attachment portions is formed by linearly bending two parts so that each part has an overall even side
Implementation Method 2
In a case where the substrate and the jig are formed of different materials, they are different in coefficient of thermal expansion
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~2D
AI summary
In a case where an electrode manufacturing operation such as heat treatment is performed on a rectangular plate-like electrode substrate that is suspended by a suspension jig, there is provided is a method for manufacturing an electrode capable of suppressing a waste of electrode substrate, preventing impairment of operability, improving flatness and the like of the electrode substrate by a simple method, and reliably preventing the electrode substrate from falling off, and simultaneously, capable of solving a problem of wrinkles and bulges that occur on the electrode due to the heat treatment and the like, thereby manufacturing a higher-quality electrode. The method for manufacturing an electrode includes: preparing a rectangular plate-like electrode substrate A formed with attachment portions A1 at two ends including opposing sides by linearly bending two parts so that each part has an overall even side; holding the attachment portions A1 by the suspension jig B1 and a lower jig each being provided with a movement restriction portion with which a leading end of each attachment portion A1 comes into contact, thereby maintaining the electrode substrate A in a suspended state; and performing at least heat treatment on the suspended electrode substrate A so as to manufacture a portion that is to be an electrode.