Secondary Battery Cap Plate Vent Forming With Fewer Forging Steps
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Solution Overview
Problem
Conventional methods for manufacturing cap plates for secondary batteries require multiple forging processes, leading to excessive hardness in safety vents due to forged hardening and increased production costs.
Innovation Solution
A method and device for manufacturing safety vents using only one or two forging processes, involving a safety vent forming step with a lower and upper elevating mold, a discharge material portion cutting and removing step, and a lower surface flattening step, which minimizes forging torque and prevents excessive hardness by forming the safety vent in a groove shape with a vent plate at the lower portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple forging processes (three times or more) are performed to form the safety vent, then the safety vent is formed with a thin vent plate portion, but the hardness of the safety vent becomes excessively high due to forged hardening
Solution Approach 1:
The patent divides the safety vent formation into two distinct stages: first forming a groove with sufficient thickness, then forming the vent plate within that groove. This segmentation prevents excessive forging on the same area, avoiding forged hardening while achieving the required thin vent plate portion.
Solution Approach 2:
The patent performs preliminary action by first forming the groove with adequate thickness before forming the vent plate. This preliminary groove formation creates a prepared structure that allows subsequent vent plate formation without requiring excessive additional forging, thereby preventing forged hardening.
2Reliability
If the forging process is performed three times or more to form the safety vent, then the safety vent is formed properly, but the unit price for producing the cap plate increases due to the increase of the number of forging times
Solution Approach 1:
The patent merges the groove formation and vent plate formation into a coordinated two-step process within a single forging operation cycle. By combining these steps and optimizing the forging sequence, the patent achieves proper safety vent formation with only two forging processes instead of three or more, thereby reducing production costs while maintaining quality.
Solution Approach 2:
The patent ensures continuity of useful action by designing the forging process to flow smoothly from groove formation to vent plate formation without unnecessary intermediate steps. This continuous process achieves complete safety vent formation in two forging operations, eliminating redundant steps and reducing production costs.
3Shape
If the vent plate is formed with thin thickness at the lower portion through multiple forging processes, then the safety vent structure is created, but forged hardening occurs at the thin portion causing excessive hardness
Solution Approach 1:
The patent applies local quality by forming the groove with sufficient thickness first, then creating the thin vent plate portion within that groove. This localized approach ensures that only the specific vent plate area is thinned, while the surrounding groove structure maintains adequate thickness, preventing forged hardening in the thin portion.
Solution Approach 2:
The patent performs preliminary action by first forming the groove with adequate thickness to serve as a foundation. This preliminary structure allows the subsequent vent plate formation to proceed with minimal additional forging, preventing forged hardening while achieving the required thin vent plate geometry.
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
Prevents forged hardening and excessive hardness in safety vents, reduces forging torque, and improves productivity by simplifying the manufacturing process to one or two forging processes, thereby lowering production costs and enhancing cap plate manufacturing efficiency.
Implementation Method 1
forming a safety vent having a groove shape and formed at a lower portion thereof with a vent plate through downward movement of the upper forming portion and the upper elevating mold and upward movement of the lower elevating mold
Data Source
AI summary
The present invention provides a method and a device for manufacturing a safety vent of a cap plate for a secondary battery, a method for manufacturing a cap plate using the method for manufacturing a safety vent, and a cap plate for a secondary battery manufactured by the method for manufacturing a cap plate, which can prevent a molding defect in a safety vent of the strength of a vent plate becoming excessively great, by easily molding the safety vent with only one or two times of forging processing in order to prevent a phenomenon in which hardening by forging occurs, during forging, in the vent plate formed at the lower part of the safety vent.