Suction Roller Joining for Short Workpiece Heat Bonding

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Solution Overview

Problem

Existing methods for joining workpieces, such as those in fuel cell manufacturing, are inadequate for short workpieces that cannot be arranged over multiple rollers, leading to issues like misalignment, deformation, and over-pressurization.

Innovation Solution

A joining device with rollers featuring protruding portions and suction mechanisms to attach and join short workpieces, along with a speed adjustment system to manage relative rotation speeds, ensuring precise and stable joining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional rollers are used to convey and join workpieces, then the joining process is simple, but short workpieces cannot be arranged over the rollers

Engineering Contradiction:

Improvecapability to join short workpiecesVSAvoidroller structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The roller surface is segmented into multiple protruding portions, each capable of independently attaching a short workpiece. This segmentation allows the roller to handle workpieces shorter than the roller circumference by providing multiple attachment points around the roller perimeter.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from a flat roller surface to a three-dimensional structure with protruding portions. This dimensional change creates additional attachment surfaces that can accommodate short workpieces by utilizing the radial dimension of the roller.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If workpieces are conveyed over multiple rollers, then alignment is maintained, but short workpieces cannot be properly positioned

Engineering Contradiction:

Improveworkpiece alignment and positioningVSAvoidworkpiece arrangement feasibility

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The protruding portions preliminarily attach and position the short workpieces on the roller surface before the joining process. This preliminary positioning ensures proper alignment is achieved even for workpieces that cannot span multiple rollers.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Different regions of the roller surface (protruding portions) have specialized local qualities for attaching and positioning workpieces. Each protruding portion is locally optimized to hold and align short workpieces precisely during conveyance and joining.

Inventive Principle:

Principle #3Local quality

3Strength

If heating and pressing is applied to join workpieces, then joining strength is achieved, but displacement and deformation occur

Engineering Contradiction:

Improvejoint strengthVSAvoidworkpiece deformation

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The protruding portions cushion and support the workpieces before heating and pressing begins. This beforehand support prevents displacement and deformation during the thermal processing by maintaining proper positioning and distributing pressure evenly.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The protruding portions act as intermediaries between the roller and the workpiece during heating and pressing. They mediate the application of heat and pressure, ensuring uniform distribution that prevents localized deformation while achieving strong joints.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of operation

If conventional rollers are used, then the device is simple to operate, but over-pressurization occurs during joining

Engineering Contradiction:

Improveoperational simplicityVSAvoidpressurization control

Core Design Contradiction:

Ease of operationVSStress or pressure

Solution Approach 1:

The pressure application is localized to the protruding portions that contact the workpieces. This local quality control prevents over-pressurization by distributing pressure only where needed, rather than applying uniform pressure across the entire roller surface.

Inventive Principle:

Principle #3Local quality

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

Enables the joining of short workpieces while minimizing displacement, deformation, and over-pressurization, and prevents warping by controlling thermal and mechanical stresses.

Implementation Method 1

a plurality of suction portions (46) that are provided to each of the protruding portions (32) and to attach the second workpiece (22) to end surfaces of the protruding portions (32)

Methodology Applied

Scientific EffectSuction: Suction

Implementation Method 2

a heater (44) that is provided to at least one of the first roller (12) or the second roller (14) and generates heat required for the joining

Methodology Applied

Scientific EffectHeat generation: Heating

Data Source

PatentUS12444728B2Joining device

Publication Date: 2025.10.14 HONDA MOTOR CO LTD

AI summary

A joining device includes a first roller that rotates an attached first workpiece in the conveying direction to convey the first workpiece, and a second roller that rotates the attached second workpiece in the conveying direction to join the second workpiece to the conveyed first workpiece by heat. The second roller includes a main body drum, a plurality of protruding portions provided at intervals in the rotational direction of the main body drum, and a plurality of suction portions that is provided to each of the protruding portions and attaches a second workpiece onto end surfaces of the protruding portions.