Prismatic Battery Cell Container Forming With Multi-Stage Ironing
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Solution Overview
Problem
Current methods for manufacturing metallic battery cell containers face challenges in achieving economic production with sufficient dimensional accuracy, particularly due to limitations in deep drawing and extrusion processes which restrict geometry and material usage.
Innovation Solution
A method involving the extrusion of a slug made from a uniform metal or metallic alloy, followed by partial ironing in multiple stations to form a prismatic battery cell container with adjustable dimensions, allowing for greater flexibility in width and length ratios and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If deep drawing method is used to manufacture battery cell container, then forming capability is improved, but the degree of forming is limited in view of the relation between the height of the battery cell container to its width
Solution Approach 1:
The manufacturing process is segmented into multiple stages: first forming a preform with initial geometry, then performing additional forming operations to achieve the final container shape with desired height-to-width ratio. This multi-stage approach overcomes the limitations of single-step deep drawing.
Solution Approach 2:
A preform is created as an intermediate stage before final container formation. This preliminary shaped workpiece serves as the basis for subsequent forming operations, enabling achievement of geometries that would be impossible to obtain directly from sheet metal.
2Loss of substance
If extrusion method is used to manufacture battery cell container, then material flow is improved, but large material usage is necessary and shaping is limited to certain geometries or dimensions
Solution Approach 1:
The process combines extrusion to create a preform with controlled material usage, followed by forming operations to achieve the final container geometry. This segmentation allows optimization of material efficiency in the extrusion stage while gaining geometry flexibility in the subsequent forming stage.
Solution Approach 2:
The method changes the geometric parameters and material distribution during the transition from preform to final container through controlled forming operations, enabling adaptation to different container dimensions and geometries while maintaining material efficiency.
3Ease of manufacture
If DI-method (deep drawing and ironing) is used to manufacture battery cell container, then manufacturing experience is improved, but manufacturing complexity increases due to requiring cup or pot fabrication first
Solution Approach 1:
The extrusion process serves multiple functions: it creates the preform structure, controls material distribution, and establishes the basic container geometry. This multi-functionality reduces the need for separate cup/pot fabrication steps, simplifying the overall process while maintaining manufacturing quality.
4Productivity
If conventional methods are used to manufacture battery cell containers, then production volume is improved, but dimensional accuracy deteriorates
Solution Approach 1:
The preform creation stage establishes precise dimensional foundations that are then refined through controlled forming operations. This preliminary action ensures that subsequent forming steps can achieve high dimensional accuracy while maintaining production efficiency.
Solution Approach 2:
The method replaces traditional mechanical forming approaches with a combination of extrusion-based material placement and controlled forming, enabling better dimensional control through more precise material flow management and reduced forming stresses.
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 enables the cost-effective production of battery cell containers with precise dimensional accuracy, particularly in height direction, while minimizing processing steps and material waste, and allows for a wide range of dimensions and geometries.
Implementation Method 1
The slug is formed into an extruded container by extrusion and for example backward extrusion
Implementation Method 2
the extruded container is formed by a first ironing and by a second ironing
Data Source
AI summary
The invention refers to a method and an apparatus (20) for manufacturing of a prismatic unilaterally open battery cell container (21). First an extruded container (41) is formed from a slug (38) by extrusion. The slug (38) consists of a uniform material. The extruded container (41) is then formed by a first ironing in a first ironing station (25) and by a second ironing in a second ironing station (28). During ironing the container is moved by a respective ironing ram (26, 29) only partly through an associated die tool (27, 30) and is reversed when reaching a reversal point (U). After the second ironing a remaining edge (82) of the obtained intermediate container (77) is separated, thereby the battery cell container (21) is obtained.