Melt-Bonding Mold Support Structure for Thermal Deformation Control
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Solution Overview
Problem
The challenge is to maintain precise heating and prevent thermal deformation in longer molds used for welding larger battery cases, as existing support systems struggle to apply uniform pressure and control heat transmission effectively, leading to warping and deformation.
Innovation Solution
The apparatus features a pair of molds with heater blocks and intermittently disposed support blocks connected via rod-like members that restrict heat transfer, including movable support blocks with a sliding mechanism to manage thermal expansion, allowing for stable and uniform pressure application and reduced thermal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the length of molds is increased to cope with larger battery cases, then the welding capacity and physical size are improved, but thermal deformation and warping increase due to heat accumulation in the support blocks
Solution Approach 1:
The support blocks are divided into multiple smaller blocks arranged intermittently along the mold length, rather than using a single continuous support block. This segmentation reduces the total length of support blocks, limiting heat accumulation and thermal deformation while maintaining structural support for the extended molds used in large battery case welding
Solution Approach 2:
Rod-like members with heat-restricting portions are introduced as intermediaries between the heater blocks and support blocks. These rod-like members transmit mechanical support forces while their narrowed middle sections restrict heat transmission, preventing thermal deformation of support blocks and maintaining mold shape precision in large-scale welding applications
2Stability of the object's composition
If highly rigid support blocks are used to maintain mold shape, then the stability is improved, but thermal deformation increases due to heat transmission from high-temperature molds over extended periods
Solution Approach 1:
Rod-like members with heat-restricting portions serve as intermediaries between heater blocks and support blocks. These members transmit mechanical forces to maintain stability while their narrowed sections block heat transmission, preventing thermal deformation of rigid support blocks and maintaining mold shape precision during extended welding operations
Solution Approach 2:
The rod-like members have different structural properties at different locations: the ends are designed for mechanical connection and force transmission, while the middle portion has a narrowed cross-section specifically designed to restrict heat transmission. This local differentiation allows simultaneous achievement of stability and thermal isolation
3Length of stationary object
If the support blocks are made longer to support extended molds, then the support coverage is improved, but the thermal deformation increases in proportion to the length increase
Solution Approach 1:
Instead of using one or two long support blocks, the system employs multiple smaller support blocks distributed intermittently along the mold length. This segmentation reduces the length of each individual support block, limiting heat accumulation and thermal deformation while providing adequate support coverage for extended molds through distributed positioning
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 configuration enables the welding of longer molds with reduced warping and deflection, ensuring uniform pressure and heat distribution, suitable for large battery packs, while minimizing thermal deformation and maintaining the shape stability of the heater blocks.
Implementation Method 1
The respective rod-like members extend in a direction that is perpendicular to the first direction and midway include parts that restrict transmission of heat
Implementation Method 2
a pair of molds that extend in a first direction and sandwich and heat an overlapping part of the plurality of film-like members
Implementation Method 3
at least one movable support block including a mechanism that moves in the first direction relative to the driving mechanism corresponding to thermal deformation in the first direction of the heater block
Data Source
Figure 1
Figure 2~4
AI summary
There is provided an apparatus 1 that includes a pair of molds 10a and 10b that press together, heat, and weld an overlapping part of a plurality of film-like members, a pair of heater blocks 20a and 20b that respectively support the pair of molds; a plurality of first support blocks 37 that are connected via a plurality of rod-like members 50, which midway include parts that restrict transmission of heat, to one heater block 20a; a plurality of second support blocks 38 that are connected via the plurality of rod-like members to the other heater block 20b; and a driving mechanism 60 that changes, via the support blocks, a gap between the pair of molds to press together the film-like members. The plurality of first support blocks include at least one movable support block 39 including a mechanism 35 that moves in a first direction relative to the driving mechanism corresponding to thermal deformation in the first direction of the heater block to be supported, and the plurality of second support blocks include at least one movable support block 39.