Rectangular Battery Can Forming With Interim Cup Ironing
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Solution Overview
Problem
Existing methods for manufacturing rectangular battery cans face challenges in achieving uniform thickness and stability due to differences in side wall areas and sharp corners, leading to increased deformation resistance, cracks, and reduced productivity.
Innovation Solution
A manufacturing method involving a first step to form an interim cup with inclined walls and curved corners, followed by a second step to gradually displace boundaries and adjust dimensions, and a third step to thin side walls, ensuring smooth material flow and stability during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the material is subjected to excessive ironing and drawing to reduce wall thickness, then the energy density and pressure withstanding strength are improved, but cracks, wrinkles, and ruptures are developed
Solution Approach 1:
The patent applies preliminary action by forming intermediate cups with controlled geometry before final drawing. The first intermediate cup has a specific height-to-diameter ratio, and the second intermediate cup has reduced minor-axis diameter, preparing the material in stages to prevent defects during final thinning
Solution Approach 2:
The manufacturing process is segmented into multiple stages: forming first intermediate cup, forming second intermediate cup with different axis ratios, then final drawing and ironing. This segmentation allows controlled material flow at each stage, preventing cracks and ruptures that would occur with single-stage excessive processing
2Manufacturing precision
If the processing amount in one cycle is reduced to avoid cracks and wrinkles, then the manufacturing quality is improved, but the number of cycles increases and productivity is reduced
Solution Approach 1:
The patent performs preliminary forming of intermediate cups with optimized geometry that facilitates subsequent drawing and ironing. The first intermediate cup is formed with specific dimensions, then the second intermediate cup reduces the minor-axis diameter, preparing the material structure for efficient final processing with higher per-cycle processing amounts
Solution Approach 2:
The patent dynamically adjusts the geometry of intermediate cups during manufacturing. The first intermediate cup has a certain height-to-diameter ratio, while the second intermediate cup has a reduced minor-axis to major-axis diameter ratio, optimizing material flow characteristics at each stage to enable higher processing amounts per cycle
3Manufacturing precision
If the corner is bent at a right angle to form rectangular cross-section, then the shape accuracy is improved, but the plastic flow becomes uneven and deformation resistance increases
Solution Approach 1:
The patent applies preliminary action by forming intermediate cups with optimized geometry before final drawing. The first intermediate cup has a specific height-to-diameter ratio, and the second intermediate cup has reduced minor-axis diameter, preparing the material in stages to prevent defects during final thinning
Solution Approach 2:
The manufacturing process is segmented into multiple stages: forming first intermediate cup, forming second intermediate cup with different axis ratios, then final drawing and ironing. This segmentation allows controlled material flow at each stage, preventing cracks and ruptures that would occur with single-stage excessive processing
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 method enables efficient production of rectangular battery cans with reduced deformation resistance, preventing cracks and ruptures, improving productivity and quality by allowing stable transportation and processing.
Implementation Method 1
a corner as a boundary between a narrower wall and a wider wall serves as a resistance against a plastic flow of the material in a circumferential direction during ironing and drawing
Data Source
AI summary
A method of manufacturing a rectangular battery includes: ironing the blank thereby forming an interim cup including an interim bottom whose area is larger than a bottom plate of the rectangular battery can, an inclined wall tilting upwardly formed continuously from each longitudinal end of the interim bottom, a short side wall formed continuously from the inclined wall, and a long side wall formed continuously from a curved corner formed on each lateral end of the interim bottom; deforming the interim cup such that each boundary between the interim bottom and the inclined wall is displaced toward a longitudinal end of the bottom plate of the rectangular battery can, and a width of the interim bottom is adjusted to a width of the bottom plate of the rectangular battery can; and ironing the short side and long side walls to reduce thicknesses of the short side and long side walls.