Lead Battery Plate Projection Forming With a Deformable Interlayer
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Solution Overview
Problem
Existing methods for producing leaded plates with projections for batteries face challenges in achieving solid projections with heights two to five times greater than the plate thickness between projections, leading to increased forming forces and difficulties in maintaining thickness tolerances due to high contact stresses and frictional forces.
Innovation Solution
A method involving a leaded workpiece, a tool with recesses, and a deformable intermediate plate, along with strips arranged between the workpiece and the tool, to exert pressure and control the flow of material into recesses, allowing for the formation of solid projections while maintaining low forming forces and adhering to thickness tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a press tool with rigid plate-shaped parts is used to compress the workpiece, then projections can be formed on the leaded plate, but the forming force increases sharply due to increasing frictional force
Solution Approach 1:
A deformable intermediate plate is introduced between the press tool and the leaded workpiece. This intermediate plate acts as a mediator that distributes the compressive force more evenly across the workpiece surface, reducing localized frictional forces and preventing the sharp increase in forming force that occurs with direct rigid plate contact.
Solution Approach 2:
The surface characteristics of the press tool are modified by using a deformable intermediate plate with specific material properties. This changes the contact parameters between the tool and workpiece, allowing for lower forming forces while still achieving the desired projection formation through controlled material flow.
2Shape
If high pressure is applied to form solid projections, then projections of desired height can be achieved, but thickness tolerances cannot be maintained due to high contact stresses
Solution Approach 1:
The deformable intermediate plate serves as a cushioning mediator that distributes contact stresses uniformly across the workpiece surface. This prevents localized high-stress regions that would otherwise cause excessive thinning and violate thickness tolerances, while still enabling the formation of solid projections through controlled plastic flow.
Solution Approach 2:
The intermediate plate is positioned beforehand between the press tool and workpiece to provide preemptive stress distribution. This cushioning effect prevents excessive contact stresses from developing during the forming process, thereby maintaining thickness tolerances while achieving the required projection height.
3Shape
If the workpiece surface area increases during compression, then material flows into recesses to form projections, but frictional force increases counter to the surface area increase
Solution Approach 1:
The deformable intermediate plate acts as a lubricating intermediary between the press tool and workpiece surface. As the workpiece surface area increases during compression, the intermediate plate maintains consistent contact with reduced friction compared to direct rigid plate contact, allowing material to flow into the recesses without being hindered by increasing frictional forces.
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 effectively forms leaded plates with projections of desired height and thickness, reducing the need for high-pressure tools and ensuring precise thickness control, thus improving the production efficiency and quality of battery components.
Implementation Method 1
When the workpiece is compressively stressed by the press tool and the yield limit of the workpiece exceeded, the workpiece will begin to flow plastically
Implementation Method 2
arranging a deformable intermediate plate, in an embodiment a planar deformable intermediate plate, between the workpiece and the upper die or lower die
Data Source
AI summary
A method for producing a leaded plate for a battery which has at least one projection comprising the steps:a) providing a leaded workpiece,b) providing a tool having a lower die and an upper die, wherein the lower die and/or the upper die have at least one recess,c) arranging the workpiece between the lower die and the upper die,d) arranging a deformable intermediate plate between the workpiece and the upper die or lower die,e) arranging a first strip and at least one second strip between the intermediate plate and the upper die or the lower die on a side of the intermediate plate facing away from the workpiece,f) executing a relative motion between the upper die and the lower die along a first direction which reduces a distance between the upper die and the lower die in order to exert pressure on the workpiece via the intermediate plate, the first strip and the at least one second strip and thereby effect a flowing movement of the material of the workpiece in a second direction running perpendicular to the first direction, whereinthe first strip and the at least one second strip are arranged spaced at a distance from one another along the second direction in step e), andsteps e) and f) are repeated multiple times so as to effect at least a portion of the material of the workpiece flowing into the at least one recess in order to form the at least one projection.