Necking-Flanging Roller Gap Design to Prevent Flange Curling
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Solution Overview
Problem
Existing battery manufacturing technologies face challenges in ensuring the quality of battery cells due to poor constraint of the free end of the flanging portion during the necking and flanging process, leading to curling issues and suboptimal winding sealing.
Innovation Solution
A necking-flanging roller with a limiting portion and guiding slope is used to constrain the free end of the flanging portion, preventing curling and ensuring accurate formation of the necking and flanging portions on the housing, which enhances the quality of the battery cell's sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the free end of the flanging portion is not constrained during necking and flanging, then the device complexity is reduced, but the manufacturing precision deteriorates due to curling and deformation
Solution Approach 1:
The roller body is segmented into functional zones: a rolling portion for forming the necking and flanging portions, and a limiting portion with a gap for constraining the free end. This segmentation allows each zone to perform its specific function independently, improving manufacturing precision without requiring a completely complex new device design.
Solution Approach 2:
The limiting portion extends in the axial direction (another dimension) relative to the rolling portion, creating a three-dimensional constraint structure. This axial extension allows the gap to effectively constrain the free end of the flanging portion, preventing curling and improving manufacturing precision through dimensional control.
2Shape
If the roller body advances significantly to form the flanging portion, then the flanging depth is improved, but the free end lifts and deforms due to lack of constraint
Solution Approach 1:
The limiting portion with its gap is positioned to preemptively constrain the free end of the flanging portion before significant deformation occurs. This preliminary constraint prevents the free end from lifting and deforming during the rolling process, maintaining manufacturing precision while allowing adequate flanging depth.
Solution Approach 2:
The gap in the limiting portion is pre-positioned along the axial direction to receive and constrain the free end of the flanging portion during the rolling process. This preliminary positioning ensures that as the roller body advances to form the flanging portion, the free end remains constrained and does not lift or deform.
3Manufacturing precision
If the limiting portion diameter is increased to better constrain the flanging portion, then the constraint effectiveness is improved, but interference with the flanging portion occurs
Solution Approach 1:
The limiting portion has a locally optimized diameter that is specifically sized to constrain the free end of the flanging portion without interference. The gap dimensions and limiting portion diameter are locally tailored to match the flanging portion geometry, ensuring effective constraint while maintaining adaptability and avoiding interference with the flanging process.
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 solution ensures high-quality winding sealing by preventing curling of the flanging portion, allowing for secure adherence of the end cap and improving the overall quality of the battery cell.
Implementation Method 1
The roller body advances toward the housing, causing deformation of the housing in the radial direction to form the necking portion
Implementation Method 2
a gap is formed between the roller body and the limiting portion, the free end of the flanging portion is inserted into the gap, and the gap restricts the free end from bending and deforming
Data Source
AI summary
A necking-flanging roller and a necking-flanging mechanism are disclosed. The necking-flanging roller is used to form the necking portion and the flanging portion on the housing, including a roller body; and a limiting portion, arranged along the axial direction of the roller body and oppositely to the roller body, wherein a gap is formed between the roller body and the limiting portion, and the gap is provided for the free end of the flanging portion to insert therein and restricts the free end from bending and deforming. The technical solution provided in the present disclosure can improve the quality of the battery.