Ultrasonic Separator Bonding Apparatus Layout for Compact Assembly
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Solution Overview
Problem
Conventional ultrasound-based bonding systems for electrical devices, such as secondary batteries, have complex structures that occupy large spaces, making them unsuitable for mass production due to their size and layout requirements.
Innovation Solution
The apparatus for bonding separators in electrical devices features a transmission unit, amplifier unit, and abutting part arranged parallel to the direction of separator conveyance, allowing for efficient ultrasonic bonding while minimizing equipment size by optimizing the layout of the horn, booster, and oscillator along the conveyance direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasound-based bonding units are used to achieve high-temperature bonding characteristics, then bonding quality is improved, but equipment size becomes large and space requirements increase
Solution Approach 1:
The patent reconfigures the spatial arrangement of ultrasonic bonding components by placing the oscillator, booster, and horn in a linear sequence along the conveyance direction rather than in a compact clustered arrangement. This dimensional reorganization allows the equipment to fit within the existing production line footprint while maintaining all necessary bonding functions, effectively resolving the contradiction between bonding quality and space occupation.
2Reliability
If complex ultrasound units with oscillators and boosters are disposed on mass production lines, then bonding performance is improved, but the dimension of the equipment becomes large
Solution Approach 1:
The patent introduces a movable horn that can be positioned and repositioned along the conveyance direction to accommodate different bonding positions and product configurations. This dynamic element allows the equipment to maintain compact dimensions while providing flexible bonding capabilities, resolving the contradiction between bonding performance and equipment length.
3Device complexity
If fixed protrusions are used in the abutting part, then bonding structure is simple, but tool life is limited due to wear
Solution Approach 1:
The patent implements a rotatable horn with replaceable protrusions that can be rotated to present fresh bonding surfaces as wear occurs. This dynamic replacement mechanism extends tool life significantly while maintaining relatively simple bonding structure, resolving the contradiction between structural simplicity and durability.
4Duration of action of stationary object
If rotatable and replaceable protrusions are implemented, then tool life is extended, but device complexity increases
Solution Approach 1:
The patent divides the horn into modular sections with interchangeable protrusions that can be independently replaced. This segmentation allows wear components to be swapped without replacing the entire horn assembly, extending tool life while keeping the overall device complexity manageable through standardized modular components.
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 configuration enables compact equipment design, reducing space requirements on assembly lines and extending tool life through rotatable and replaceable protrusions, thus enhancing production efficiency and cost-effectiveness.
Implementation Method 1
a transmission unit that generates ultrasonic oscillations, an amplifier unit that amplifies the generated oscillations, and an abutting part that applies the amplified oscillations to a pair of separators 40
Data Source
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Figure 2
Figure 3~4
AI summary
[Problem] To provide an apparatus for bonding separators in electrical devices wherein even if a unit that performs bonding using ultrasound is used in assembly-line equipment, the amount of space taken up by said equipment can be kept small. [Solution] The present invention is an apparatus 100 for bonding separators in electrical devices, which is used to bond a pair of separators 40 to each other so as to sandwich an electrode 20, provided with an oscillator 153 that generates ultrasonic oscillations; a booster 152 that amplifies the generated oscillations; a horn 151 that applies the amplified oscillations to the pair of separators so as to bond said separators to each other; and separator conveyance units 120, 130 that convey the pair of separators to a bonding position where the horn bonds said separators to each other, wherein the oscillator, the booster, and the horn are laid out in a plane that is parallel to the direction X in which the separators are conveyed and perpendicular to the surfaces of the separators, or the oscillator and the booster are laid out closer to the widthwise centers of the separators than the horn is when seen from a direction that is parallel to the direction in which the separators are conveyed.