Metallic Electrode Carrier Structure With Closed Weldable Edge Regions
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Solution Overview
Problem
Existing methods for producing metallic carrier structures for electrodes using stretch metal grilles or wire fabrics struggle with maintaining structural integrity and closing openings in the edge areas, which affects the static properties and connectivity of the carrier structures.
Innovation Solution
A procedure involving the conversion of edge areas of flat material sections by orthogonal rolling or shaping to close openings through plastic deformation, followed by overlapping and welding of these converted areas to form a robust metallic carrier structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If edge regions of flat material sections are formed by exerting pressure to close openings through plastic deformation, then welding reliability and static properties are improved, but device complexity and processing time increase
Solution Approach 1:
The edge regions are pre-formed by exerting pressure to close openings through plastic deformation before the welding process. This preliminary action ensures that the edge regions have the necessary structural integrity and closed openings for reliable welding, eliminating the need for more complex welding preparation processes.
Solution Approach 2:
The physical state of the edge regions is changed by applying pressure to induce plastic deformation, transforming the open expanded metal grid structure into a closed, dense edge region. This parameter change in the material structure enables reliable welding while maintaining processing simplicity.
2Strength
If pressure is exerted orthogonally on edge regions to close openings by plastic deformation, then structural integrity is improved, but manufacturing time and energy consumption increase
Solution Approach 1:
The edge regions are pre-formed by exerting pressure to close openings through plastic deformation before the welding process. This preliminary action ensures that the edge regions have the necessary structural integrity and closed openings for reliable welding, eliminating the need for more complex welding preparation processes.
Solution Approach 2:
The physical state of the edge regions is changed by applying pressure to induce plastic deformation, transforming the open expanded metal grid structure into a closed, dense edge region. This parameter change in the material structure enables reliable welding while maintaining processing simplicity.
3Area of stationary object
If flat material sections are welded together after forming edge regions, then large-area carrier structures can be produced, but the complexity of the production process increases
Solution Approach 1:
The large-area carrier structure is divided into multiple flat material sections that are processed individually with formed edge regions, then welded together. This segmentation allows for simpler individual component manufacturing while achieving the desired large final area through assembly.
Solution Approach 2:
Multiple flat material sections with formed edge regions are welded together to create a large-area carrier structure. This merging of simpler components achieves the desired large scale without requiring complex single-piece manufacturing processes.
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 method effectively closes edge openings by at least 95%, ensuring enhanced static properties and seamless welding, thereby enabling the production of large-scale, process-proof carrier structures for electrodes with uniform thickness and desired shapes.
Implementation Method 1
forming the edge regions of the flat material sections to be welded together by exerting pressure orthogonally on these edge regions, in particular by rolling or embossing, in order to at least almost dissolve an expanded metal grid structure or fabric structure by plastic deformation in the edge regions
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
A method for producing a metallic carrier structure (32, 38) for an electrode (40). The carrier structure (32, 38) is formed from flat material portions (10, 10') of an expanded metal mesh (12) or wire fabric (20) with openings (16, 16'). At least two flat material portions (10, 10') are welded to one another in a respective edge region (18, 18').