Separator Welding Device Integrating Fastening and Thermal Joining
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Solution Overview
Problem
The existing method of packaging electrodes between separators involves separate processes for fastening and thermal welding, leading to increased cycle time and reduced manufacturing efficiency.
Innovation Solution
A separator welding device with moving joining heads and holding units that fasten and weld separators simultaneously, reducing cycle time by integrating fastening and welding into a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fastening and thermal welding of separators are performed in separate processes, then each process can be optimized independently, but cycle time is increased and manufacturing efficiency is reduced
Solution Approach 1:
The patent combines the fastening unit and thermal welding unit into a single integrated device that performs both operations simultaneously on the separators. The fastening unit applies clamping force while the thermal welding unit applies heat and pressure, merging two previously separate processes into one coordinated operation that reduces cycle time while maintaining quality
Solution Approach 2:
The joining head is designed as a multi-functional device that incorporates both fastening and thermal welding capabilities. The same joining head structure supports both the fastening unit with clamping arms and the thermal welding unit with heating elements, allowing one device to perform multiple functions that previously required separate equipment
2Productivity
If holding units are mounted on joining heads to enable simultaneous fastening and welding, then cycle time is reduced, but device complexity is increased
Solution Approach 1:
The holding units are nested within or integrated into the joining head structure. The clamping arms of the fastening unit are positioned within the joining head, and the thermal welding elements are arranged to work in conjunction with the fastening mechanism. This nesting approach allows multiple functional components to occupy the same spatial envelope, reducing overall device complexity while enabling simultaneous operations
3Reliability
If holding units retract from advanced position during welding, then separator peeling is prevented, but control complexity is increased
Solution Approach 1:
The holding units are designed to retract from the advanced position before the thermal welding process begins. This preliminary retraction action prevents the separators from peeling during welding while ensuring they remain properly positioned and fastened. The timing of this retraction is controlled as part of the overall welding sequence, integrating the motion control into the existing process timing
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 approach shortens the cycle time required for welding separators, enhancing manufacturing efficiency and ensuring accurate joining without peeling of the separators.
Implementation Method 1
A biasing member is provided between the joining head and the holding unit, and biases the holding unit with a biasing force that moves the holding unit towards the advanced position
Implementation Method 2
the distal ends of the joining tips come into contact with the separators and join the separators to each other
Data Source
AI summary
A production device 100 for a packaged electrode 20, to which a separator welding device is applied, includes joining heads 301 having joining tips 302 and 303 that join a pair of separators 30 to each other and holding units 304 that fasten the pair of separators. After the joining heads 301 are moved closer to each other with respect to the separators, and the separators are fastened by the holding units 304, the pair of separators is joined to each other by the joining tips 301. Meanwhile, after the joining heads 301 are separated from each other with respect to the separators, and the joining tips are separated from the pair of separators, the separators are released from fastening by the holding units 304.