Layer Turner Stacking for Precise Fuel Cell Module Assembly
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Solution Overview
Problem
Existing manufacturing processes for fuel or battery cells face inefficiencies and precision issues in stacking layered materials, leading to potential tearing of separators and inconsistent cell stack quality.
Innovation Solution
A device and method utilizing first and second conveyors with layer turners that rotate anode and cathode layers by specific angles, combined with a stacking table that moves back and forth, allowing for precise and rapid stacking of alternating layers with radial retraction of receivers to minimize distance and prevent collisions, using controlled pneumatic pressure for handling layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If silicon wafers are manually loaded into batch furnaces one by one, then the furnaces can be loaded, but the process requires extremely high precision and takes a long time
Solution Approach 1:
The loading process is segmented into discrete steps: positioning the wafer on the loading plate, lowering the plate to the transfer robot, transferring to the transfer arm, and placing in the furnace. This segmentation allows automation while maintaining precision through controlled transitions at each stage.
Solution Approach 2:
A transfer robot with a transfer arm serves as an intermediary between the loading plate and the furnace. This intermediary device enables automated high-precision transfer without direct manual handling, resolving the contradiction between speed and precision.
2Productivity
If automated transfer robots are used to move silicon wafers, then loading speed improves, but the system complexity increases
Solution Approach 1:
The transfer robot with its movable arm serves multiple functions: picking up wafers from the loading plate, transporting them to different furnace positions, and placing them in the furnace. This multi-functionality reduces the need for multiple specialized devices, managing system complexity while maintaining high productivity.
3Quantity of substance
If batch furnaces are used for silicon wafer processing, then processing capacity increases, but the processing time for each wafer increases
Solution Approach 1:
While one batch of wafers is being processed in the furnace, the transfer robot continuously loads new wafers onto the loading plate and transfers them to the furnace as batches complete. This continuous operation ensures that the furnace is always working at full capacity without idle time, maximizing processing capacity while minimizing wait time per wafer.
Data Source
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AI summary
A method and a device serve for producing modules or precursors of modules, in particular fuel cells or battery cells containing layer material. The method comprises the following steps performed by the device: conveying individual anode layers to a first transfer point for transfer to a first layer turner; conveying individual cathode layers to a second transfer point for transfer to a second layer turner; picking up respective individual anode or cathode layers at the respective first or second transfer point by means of corresponding pickups of a respective first or second layer turner; turning the picked-up individual anode or cathode layers by a respective angle of rotation in relation to a respective first or second depositing point; moving a stack table back and forth between the first depositing point and the second depositing point by a drive; depositing the respective individual anode or cathode layer at the first or second depositing point, respectively, onto the stack table when the latter is located at the first or second depositing point; and radially retracting the pickup of the first and/or the second layer turner when it approaches the pickup of the other layer turner.