Two-Stage Molding Device for Pouch Battery Cases
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Solution Overview
Problem
The issue of reduced aluminum residual rate and increased risk of cracks and disconnection during the formation of pouch-type battery cases due to concentrated stress at the corner edges during punch pressing.
Innovation Solution
A forming apparatus comprising a first die, a second die, a stripper, and a punch, with a connection part and compression member to facilitate two-stage pressing, dispersing stress and preventing cracks by increasing the stretched portion of the object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If punch pressing is performed on pouch film to form cup part, then forming operation is completed, but aluminum residual rate is lowered due to stretching at corner edges
Solution Approach 1:
The pressing operation is divided into two distinct stages: first pressing with the punch to create initial deformation, then second pressing with the second die to complete the forming. This segmentation allows stress to be distributed more evenly across the pouch film, particularly at corner edges, reducing excessive stretching and aluminum material loss while achieving the desired cup part formation.
Solution Approach 2:
The first die performs a preliminary pressing action before the second die completes the forming operation. This preliminary action pre-deforms the pouch film in a controlled manner, preparing it for the final forming stage and preventing concentrated stress at corner edges during the main pressing operation, thereby preserving aluminum residual rate.
2Manufacturing precision
If punch presses pouch film to perform forming operation, then cup part is formed, but stress is concentrated at corner edge causing cracks and disconnection
Solution Approach 1:
The forming operation is segmented into two pressing stages using different dies. The first die performs initial pressing to create gradual deformation, while the second die completes the forming. This segmentation distributes stress over time and space, preventing stress concentration at corner edges that would otherwise cause cracks and disconnection, ensuring reliable cup part formation.
Solution Approach 2:
The pressing process is made dynamic through sequential operation of two dies. The first die presses initially, then the second die presses subsequently, creating a time-dependent deformation process. This dynamic approach allows the material to gradually adapt to stress, preventing sudden stress concentration that leads to cracks and disconnection during forming.
3Manufacturing precision
If deeper forming is performed to increase stretched portion, then forming depth is improved, but wrinkles are developed due to stress concentration
Solution Approach 1:
The deep forming operation is divided into two pressing stages. The first die performs initial pressing to create gradual deformation and increase the stretched portion. The second die then completes the forming to achieve deeper cup parts. This segmentation allows stress to be distributed evenly throughout the deformation process, enabling deeper forming without causing wrinkles that would result from concentrated stress.
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
Prevents cracks and disconnection while enhancing the residual rate of the pressed object by increasing the stretched portion, allowing for deeper forming without wrinkles.
Implementation Method 1
a connection part configured to connect the first die to the second die and provided with a compression member
Implementation Method 2
The compression member may include at least one of a spring or a cylinder
Data Source
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AI summary
The present invention relates to a forming apparatus and a forming method. The forming apparatus includes a first die, a second die disposed inside the first die to press an object to be pressed, a stripper disposed to face the first die and the second die so as to press the object to be pressed, a connection part configured to connect the first die to the second die and provided with a compression member, and a punch disposed inside the second die to press the object to be pressed, wherein the second die is configured to press the object to be pressed after the object to be pressed is compressed by the first die and the stripper.