Pouch Case Forming via Fluid Pressure and Mold Intermediary

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Solution Overview

Problem

Conventional deep drawing processes for forming pouch cases in secondary batteries often result in surface damage, defects, and limited shape flexibility due to direct contact with metal forming dies, leading to reduced quality and yield.

Innovation Solution

An apparatus and method using a mold with a chamber that minimizes surface contact through guide forming and pressure forming with a fluid, allowing the pouch case to conform to a shape without direct contact with a forming die, utilizing a fluid supply unit and heating to optimize deformation without material damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If deep drawing process using metal forming die is used, then pouch case can be formed with concave inner space, but surface damage and defects occur due to direct contact with forming die

Engineering Contradiction:

Improveconcave inner spaceVSAvoidsurface damage

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a mold as an intermediary element between the forming die and the pouch case. The mold has a cavity that receives the pouch case, and the forming die forms the pouch case indirectly by pressing against the mold cavity rather than directly contacting the pouch case surface. This intermediary structure allows the pouch case to acquire the desired concave shape while preventing direct contact damage to its surface.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If deep drawing process using forming die is used, then pouch case can be formed, but quality and yield are reduced due to defects and cracking

Engineering Contradiction:

Improveforming processVSAvoidforming quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The mold serves as a protective intermediary that distributes forming pressure uniformly across the pouch case surface. The pouch case is placed in the mold cavity, and the forming die presses against the mold rather than directly on the pouch case, preventing stress concentration and cracking while maintaining manufacturing efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mold cavity is designed beforehand to match the desired final shape of the pouch case. This pre-prepared cushioning structure receives and protects the pouch case during forming, preventing defects before they occur by providing a controlled forming environment that distributes stress evenly.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Device complexity

If direct contact forming with metal die is used, then forming process is simple, but shape flexibility is limited

Engineering Contradiction:

Improveforming processVSAvoidshape flexibility

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The forming system is segmented into three independent components: the mold cavity (defining the shape), the pouch case (the workpiece), and the forming die (applying pressure). This segmentation allows the mold cavity to be redesigned for different shapes without changing the forming die, providing shape flexibility while keeping the overall process simple.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the forming parameter from direct mechanical contact to indirect contact through a mold cavity. This parameter change enables the pouch case to be formed into various complex shapes by modifying the mold cavity design rather than redesigning the entire forming system, enhancing adaptability while maintaining process simplicity.

Inventive Principle:

Principle #35Parameter changes

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 approach reduces surface damage, enhances forming quality, and allows for more complex shapes with reduced stress concentration, minimizing defects like cracking and ensuring uniformity in the pouch case production.

Implementation Method 1

a fluid supply unit configured to supply a fluid via the fluid input valve to carry out pressure forming of the pouch case to conform to the mold

Methodology Applied

Scientific EffectFluid pressure: Pressure Increase

Implementation Method 2

utilizing a fluid supply unit and heating to optimize deformation without material damage

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS10933575B2Apparatus and method for forming pouch case for secondary battery

Publication Date: 2021.03.02 LG ENERGY SOLUTION LTD

AI summary

An apparatus and method are provided for forming a pouch case with improved forming quality and minimized surface contact between the forming apparatus and the pouch case in the forming process to form a pouch cup. The apparatus includes a mold on which a pouch case with a plate shape can be placed, wherein the mold bulges upwards, a chamber open at bottom to the pouch case and the mold, the chamber having an inner space in which the mold can be received by lift-up of the mold or lift-down of the chamber, wherein the chamber is seated on an edge portion of the pouch case, and the chamber is equipped with a fluid input valve at top and a fluid output valve at bottom, and a fluid supply unit configured to supply a fluid via the fluid input valve to carry out pressure forming of the pouch case.