Square Can Shape Correction for Wall Expansion and Flat Bottoms
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Solution Overview
Problem
The manufacturing of square cans, particularly those used as lithium-ion battery cases, faces issues with shape accuracy due to material flow differences causing internal stress and deformation, such as the 'canning phenomenon, and unwanted swell of the bottom wall during the drawing and ironing process, which complicates the production and increases manufacturing burden.
Innovation Solution
A square can manufacturing method and apparatus that includes a shape correction unit to expand the distance between long side walls and planarize the bottom wall by using a shape correction punch and a bottom wall pressing member, allowing for improved shape accuracy without the need for additional apparatus structures that increase cost and reduce manufacturing speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If drawing and ironing are performed multiple times to form a square cylindrical part, then the square can is manufactured, but material flow differences cause internal stress and canning phenomenon leading to poor shape accuracy
Solution Approach 1:
The invention introduces a shape correction step that is performed preliminarily after drawing and ironing, but before final product completion. The shape correction punch proactively corrects internal stress and canning phenomenon by applying targeted pressure to the square cylindrical part, preventing these defects from affecting the final product quality.
Solution Approach 2:
The shape correction punch acts as an intermediary tool between the drawing/ironing process and the final product. It mediates the material flow issues and internal stress problems by providing controlled pressure distribution, transforming the defective intermediate product into a high-quality final product without requiring complete process redesign.
2Manufacturing precision
If conventional drawing and ironing processes are used, then square can is formed, but bottom wall swell occurs reducing shape accuracy
Solution Approach 1:
The shape correction punch applies different pressure characteristics to different regions of the square cylindrical part. The pressure distribution is optimized locally - applying greater pressure to the bottom wall area to suppress swell, while maintaining appropriate pressure on the side walls. This localized quality control achieves bottom wall flatness without requiring uniform process changes throughout the entire manufacturing system.
3Manufacturing precision
If additional apparatus structures are added to improve shape accuracy, then manufacturing precision improves, but apparatus complexity and cost increase
Solution Approach 1:
The shape correction punch is designed as a multi-functional tool that can be integrated into existing drawing and ironing equipment. It serves both as a forming tool and a correction tool, eliminating the need for separate correction apparatus. The punch structure incorporates pressure distribution mechanisms that address multiple defects (canning phenomenon, bottom wall swell, internal stress) simultaneously, reducing overall apparatus complexity while improving shape accuracy.
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 method enhances the shape accuracy of square cans while minimizing the manufacturing burden, avoiding the need for complex apparatus configurations that would otherwise increase costs and reduce production speed.
Implementation Method 1
pushing the planned long side wall parts outward in the short side direction by a long side wall pressing part
Implementation Method 2
planarized by sandwiching the planned bottom wall part between a bottom wall pressing part and a bottom wall pressing member
Data Source
AI summary
Provided are a square can manufacturing method and a square can manufacturing apparatus. The square can manufacturing method includes a shape correction step of correcting the shape of an intermediate molded product, and in the shape correction step, a distance in a short side direction between planned long side wall parts of the intermediate molded product is expanded by pushing the planned long side wall parts outward in the short side direction by a long side wall pressing part of a shape correction punch inserted in the intermediate molded product, and a planned bottom wall part of the intermediate molded product is planarized by sandwiching the planned bottom wall part between a bottom wall pressing part of the shape correction punch inserted in the intermediate molded product and a bottom wall pressing member disposed on an outer surface side of the planned bottom wall part.