Integrated Electrode Assembly for Precise Low-Scrap Manufacturing
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Solution Overview
Problem
Conventional electrode assemblies require multiple fabrication steps, are prone to misalignment and damage during assembly, and result in significant scrap material, leading to increased production costs.
Innovation Solution
A novel electrode assembly design featuring a substrate with integrated electrode and wiring connection structures, secured by interference fits and overmolding, which reduces misalignment and damage, and minimizes scrap material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional electrode assemblies use multiple separate components and fabrication steps, then assembly flexibility is maintained, but manufacturing complexity and production time increase
Solution Approach 1:
The patent combines multiple separate components (electrode, wiring connection structure, and substrate) into a single integrated assembly. The electrode is directly formed on the substrate with integrated wiring connections, eliminating the need for separate assembly steps and reducing manufacturing complexity while improving production efficiency.
2Manufacturing precision
If conventional electrode assemblies use multiple separate components, then component replacement is easier, but misalignment and damage during assembly increase
Solution Approach 1:
The electrode and wiring connection structures are integrated into a single unitary assembly formed directly on the substrate. This integration eliminates misalignment issues between separate components and reduces the risk of damage during assembly operations, as there are no separate parts to handle and align.
3Productivity
If conventional electrode assemblies use traditional fabrication methods, then production volume can be maintained, but scrap material generation increases
Solution Approach 1:
The integrated design allows the electrode and wiring structures to be formed as a single unit directly on the substrate using additive or co-forming techniques. This eliminates the need for separate fabrication and assembly steps that generate significant scrap material, reducing waste while maintaining production volume.
4Strength
If conventional electrode assemblies use separate components, then design modification is easier, but structural integrity decreases
Solution Approach 1:
The electrode, wiring connection structure, and substrate are formed as an integrated assembly where the wiring structure is directly embedded in or formed with the substrate. This integration significantly improves structural integrity and mechanical strength by eliminating interfaces and potential failure points between separate components.
Data Source
AI summary
An electrode assembly includes a substrate, a plurality of electrodes, and a wiring assembly. The substrate includes an elongate body extending from a first end to a second end in a first direction and a plurality of electrode connection structures connected with the elongate body. Each electrode connection structure defines a first coupling end, a second coupling end, and a first opening positioned between the first coupling end and the second coupling end. The electrodes are positioned within the plurality of electrode connection structures. A portion of each electrode extends through the first opening of the respective electrode connection structure. The wiring assembly extends along the substrate and forms an electrical connection with each of the plurality of the electrodes.