Top Patch Hole Geometry for Faster Offcut Removal
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Solution Overview
Problem
The existing methods for manufacturing top patches for energy-storage apparatuses are inefficient due to the difficulty in removing offcuts, leading to increased machining time and decreased production efficiency.
Innovation Solution
A top patch design featuring a smooth aluminum sheet with a top patch attached, incorporating a first terminal through-hole, a second terminal through-hole, and a first explosion-proof valve through-hole, with obliquely arranged hole walls and extension bumps to facilitate easier removal of offcuts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the top patch is manufactured by cutting a sheet and removing offcuts, then the top patch can be adapted to the shape of functional parts, but the machining time increases and production efficiency decreases
Solution Approach 1:
The hole walls are pre-formed with oblique arrangements during the sheet cutting process, creating self-loosening structures that facilitate subsequent offcut removal. The extension bumps are also formed in advance on the side walls, which will later engage with the offcuts to enable easy detachment without additional machining steps.
2Ease of operation
If the hole walls are arranged obliquely with angles between 25 to 85 degrees, then the offcuts become easier to remove, but the manufacturing complexity increases
Solution Approach 1:
The hole walls are designed with asymmetric oblique arrangements at specific angles (25-85 degrees) rather than vertical or horizontal orientations. This asymmetric geometry creates natural leverage points that facilitate offcut removal while the angles are optimized to balance ease of removal with manufacturability using standard cutting tools.
3Ease of operation
If extension bumps are added to the side walls of the first hole, then the offcuts can be easily removed, but the manufacturing process becomes more complex
Solution Approach 1:
The side walls of the first hole are segmented with protruding extension bumps at specific positions. These bumps divide the continuous side wall into distinct sections that can engage with offcuts at multiple points, providing leverage for removal. The bumps are integrated into the cutting process rather than added as separate components.
Data Source
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AI summary
A top patch, an energy-storage apparatus, and an electricity-consumption device are provided in the present disclosure. The top patch defines a first terminal through-hole and a first hole spaced apart from the first terminal through-hole in a length direction of the top patch, the first hole includes two side walls arranged opposite to each other in a width direction of the top patch, each of the two side walls is provided with an extension bump, the first hole at one side of the extension bump forms a first explosion-proof valve through-hole, the first hole at the other side of the extension bump forms a second terminal through-hole, the top patch further includes a connecting surface configured to be connected to the smooth aluminum sheet, each of a hole wall of the first terminal through-hole, a hole wall of the second terminal through-hole, and a hole wall of the first explosion-proof valve through-hole is arranged obliquely relative to the connecting surface, and an angle at which each of the hole wall of the first terminal through-hole, the hole wall of the second terminal through-hole, and the hole wall of the first explosion-proof valve through-hole is inclined relative to the connecting surface ranges from 25 degrees to 85 degrees. According to the technical solutions of the present disclosure, offcuts of the top patch can be more easily taken out from the sheet of the top patch, thereby saving machining time costs of the top patch.