Vacuum-Assisted Pouch Forming to Prevent Cracks and Bulging
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Solution Overview
Problem
Existing pouch forming methods for secondary batteries, particularly pouch-type batteries, face issues such as cracks and bulging due to material limitations and stress concentration during the forming process, which affect the manufacturing quality and efficiency.
Innovation Solution
A pouch forming device and method that utilizes a die portion, punch portion, forming support portion, and control unit to control the forming process, employing vacuum pressure and synchronized movements to reduce stress concentration and prevent bulging, ensuring precise shaping of the pouch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional pouch forming methods are used, then the forming process is simple, but cracks and bulging occur due to stress concentration
Solution Approach 1:
The forming device is segmented into multiple functional components: a die portion with forming grooves, a punch portion for applying force, and a forming support portion with evacuation capability. This segmentation allows each component to perform its specific function optimally, preventing stress concentration and forming defects while maintaining manageable device complexity
Solution Approach 2:
The forming support portion acts as an intermediary between the die portion and the pouch sheet. It provides controlled support and evacuation during the forming process, distributing stress evenly and preventing both cracks and bulging. This intermediary component enables precise control over the forming mechanism
2Quantity of substance
If deep forming is performed to increase energy density, then battery capacity improves, but material stress concentration causes cracks and defects
Solution Approach 1:
The forming support portion performs preliminary evacuation of the internal space before and during the forming process. This preliminary action creates a controlled environment that prevents material defects and stress concentration, enabling deep forming to achieve higher energy density while maintaining pouch integrity
Solution Approach 2:
The device controls forming parameters by adjusting the evacuation level, pressing force, and forming speed. By optimizing these parameters, the system achieves deep forming for increased energy density while preventing stress concentration that would cause cracks and maintain overall reliability
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
The method effectively prevents cracks and bulging, allowing for deeper forming and improved energy density in secondary batteries by distributing stress evenly and controlling the forming process.
Implementation Method 1
a vacuum device forming vacuum pressure in the internal space
Data Source
AI summary
A pouch forming method may include: a disposing operation of disposing a pouch sheet between a die portion including a forming lower surface on which a pouch sheet is formed and a forming support portion disposed on the forming lower surface and a punch portion for forming the pouch sheet; a first forming operation of evacuating an internal space of the die portion and lowering the forming support portion in a direction of the forming lower surface to bend the pouch sheet; and a second forming operation of lowering the punch portion in a direction of the forming lower surface to press the pouch sheet.