Multi-Angle Roller Crimping for Thick-Walled Cylindrical Cells
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Solution Overview
Problem
The crimping process of cylindrical secondary cells is inefficient and prone to deformation of the battery case, especially in thick-walled cells, due to the need for multiple molds and complex control, leading to increased costs and defects.
Innovation Solution
A crimping apparatus with a roller that includes multiple inclined parts with different angles, allowing for sequential pressing and bending of the battery case opening, reducing the need for multiple molds and improving process efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple molds are used for crimping thick-walled battery cases, then the crimping process can be completed, but the device complexity and manufacturing cost increase
Solution Approach 1:
The roller is divided into multiple independent inclined parts (first inclined part, second inclined part, third inclined part) with different inclination angles. Each inclined part corresponds to a different crimping stage, allowing sequential pressing actions to be performed by a single roller instead of multiple molds. This segmentation of functional zones on a single component resolves the contradiction by maintaining crimping quality while reducing device complexity.
Solution Approach 2:
A single roller is designed to perform multiple crimping functions through its different inclined parts. The first inclined part performs initial pressing, the second inclined part performs secondary pressing, and the third inclined part performs final pressing. This multi-functionality allows one roller to replace what would traditionally require multiple specialized molds, reducing device complexity while maintaining comprehensive crimping capability.
2Manufacturing precision
If multiple molds are used for crimping, then complete crimping can be achieved, but the manufacturing cost increases
Solution Approach 1:
Multiple crimping functions that would traditionally require separate molds are merged into a single roller component. The roller integrates the first inclined part, second inclined part, and third inclined part, each performing a specific crimping stage. This consolidation reduces the number of components that need to be manufactured, inventoried, and maintained, thereby reducing manufacturing cost while preserving complete crimping capability.
Solution Approach 2:
The single roller is designed with multi-functionality to perform all crimping stages (initial pressing, secondary pressing, final pressing) that would otherwise require multiple specialized molds. This universality eliminates the need to manufacture and purchase multiple separate molds, directly reducing manufacturing cost while maintaining crimping quality.
3Manufacturing precision
If complex control is used for multiple molds, then crimping can be completed, but the process time and efficiency increase
Solution Approach 1:
The roller is segmented into multiple inclined parts that perform crimping stages sequentially in a single continuous motion. The first inclined part, second inclined part, and third inclined part engage the battery case opening in sequence as the roller moves, eliminating the need for complex coordination between multiple independent molds. This segmentation simplifies control while maintaining crimping quality.
Solution Approach 2:
The crimping process is performed continuously in a single rolling motion without interruption or repositioning. As the roller moves along the battery case opening, all inclined parts perform their respective pressing functions in continuous sequence. This eliminates the downtime and complex coordination required when using multiple molds that would need to be positioned and activated separately, thereby improving productivity while maintaining crimping quality.
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 apparatus prevents deformation of the battery case and reduces manufacturing costs by using a single roller for multiple bending processes, enhancing the crimping efficiency and reducing defects.
Implementation Method 1
a roller connected to the roller support device and configured to press an opening part of the battery case
Implementation Method 2
the roller may include at least two or more inclined parts having different inclined structures
Data Source
AI summary
A crimping apparatus according to an exemplary embodiment of the present disclosure includes: a roller support device disposed to be movable up and down in an axial direction of a battery case; and a roller connected to the roller support device and configured to press an opening part of the battery case, wherein the roller may be disposed to be movable in a radial direction of the battery case.