Metal Foil Core Structure to Reduce Sagging During Transport
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Solution Overview
Problem
Metal foils used in manufacturing secondary batteries and flexible printed circuit boards are prone to sagging and deformation during transportation due to continuous loading and vibrations, leading to defects such as machine direction buckle and fusilli.
Innovation Solution
A metal foil core with a winding member and protrusion members featuring inducing grooves to distribute load and reduce deformation, incorporating specific groove positioning and depth ratios to minimize defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metal foil is wound around a core for transportation, then the metal foil can be transported efficiently, but the core may sag and deform due to continuous load and vibrations
Solution Approach 1:
The core is divided into multiple protrusion members (first protrusion member, second protrusion member, etc.) that are spaced apart along the winding member. Each protrusion member independently supports the metal foil, distributing the load and preventing concentrated stress that would cause sagging and deformation during transportation.
Solution Approach 2:
Inducing grooves are formed at specific locations on the protrusion members (between both ends in the first axis direction) to create localized structural features that induce controlled deformation in the protrusion members themselves, preventing stress transmission to the metal foil and maintaining core stability during transport.
2Ease of manufacture
If the core structure is simplified for ease of manufacture, then manufacturing cost decreases, but the core becomes more susceptible to sagging and deformation under load
Solution Approach 1:
Inducing grooves with curved cross-sections are formed on the protrusion members. These curved grooves provide structural reinforcement that increases the protrusion members' resistance to sagging and deformation under load, while the grooves themselves can be formed using standard machining operations, maintaining manufacturing simplicity.
3Stability of the object's composition
If the core structure is made more complex with additional features to prevent deformation, then core stability improves, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of providing continuous support along the entire length of the core, inducing grooves are formed only at specific partial locations (between both ends of the protrusion members in the first axis direction). This partial action provides sufficient stability to prevent metal foil deformation while avoiding the complexity of a fully reinforced core structure.
Data Source
AI summary
The present disclosure relates to a metal foil core including a winding member around which a metal foil is wound, a first protrusion member protruding from the winding member in a first direction (direction of arrow FD) of a first axis direction (X-axis direction), a second protrusion member protruding from the winding member in a second direction (direction of arrow SD) opposite to the first direction (direction of arrow FD) of the first axis direction (X-axis direction), and a first inducing groove formed in the first protrusion member to be disposed between both ends of the first protrusion member in the first axis direction (X-axis direction).