Separator Roll Splicing With Ultrasonic Bonding and Film Removal
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Solution Overview
Problem
Existing methods for supplying raw materials to secondary battery separators face issues with non-uniform bonding strength due to adhesive tapes, require manual intervention, and complicate the process with the need to remove protective films, leading to inefficiencies.
Innovation Solution
A raw material supply device that uses ultrasonic waves to automatically bond the end portions of existing and supplied separator materials, allowing for seamless integration and removal of protective films without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bonding tape is used to bond the end portions of raw materials, then the raw materials can be bonded together, but the bonding strength is not uniform and additional process requirements are introduced
Solution Approach 1:
The patent replaces the mechanical bonding method using bonding tape with ultrasonic wave bonding. The ultrasonic bonding device uses high-frequency mechanical vibrations to directly bond the end portions of raw materials, eliminating the need for bonding tape and achieving uniform bonding strength through controlled ultrasonic energy application.
Solution Approach 2:
The patent changes the bonding method from adhesive-based mechanical bonding to ultrasonic vibration-based bonding. By controlling ultrasonic parameters (frequency, amplitude, duration), the bonding strength becomes uniform and controllable, resolving the non-uniform bonding issue while simplifying the overall process.
2Ease of operation
If manual intervention is used for raw material bonding and protective film removal, then these tasks can be completed, but work efficiency is reduced
Solution Approach 1:
The patent implements an automated system where the ultrasonic bonding device performs both bonding and protective film removal operations automatically. The system self-regulates the bonding process and film removal without requiring manual intervention, thereby maintaining operational simplicity while significantly improving work efficiency through automation.
Solution Approach 2:
The patent performs protective film removal as a preliminary action before bonding. The automated system removes the protective films from the end portions of raw materials in advance, then immediately proceeds with ultrasonic bonding, eliminating the need for separate manual operations and improving overall productivity.
3Object-affected harmful factors
If protective films are attached to raw materials for protection, then the raw materials are protected, but the bonding process becomes more complex
Solution Approach 1:
The patent extracts and removes the protective films from the end portions of raw materials as a preliminary step before bonding. The automated system cleanly separates and removes the protective films, allowing the bonding process to proceed without complexity while the bulk of the raw materials remain protected by their protective films.
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 device simplifies the bonding process, enhances adhesion strength, and automates the handling of protective films, improving operational efficiency and reducing manual work.
Implementation Method 1
a bonding unit 20 configured to bond the end portion of the supplied raw material R1 and the end portion of the existing raw material R2
Implementation Method 2
capable of automatically bonding an existing raw material and a supplied raw material using ultrasonic waves
Data Source
Figure 1~2a
Figure 2b~2c
Figure 3a
AI summary
The present invention provides a raw material supply device for a separator of a secondary battery comprising a conveying unit for causing the end portion of the supplied raw material to move to the end portion of the existing raw material; and a bonding unit for bonding the end portion of the supplied raw material and the end portion of the existing raw material. The raw material supply device may automatically bond the existing raw material and the supplied raw material by using ultrasonic waves with respect to the raw material for the separator of the secondary battery in the form of a roll.