CRIMPING DIE EMPLOYING POWERED CHUCK

Abstract: A forming die includes a base and at least two die segments. At least a first one of the die segments is moveably mounted to the base for shifting between closed and opened positions. The die segments together define a cavity having an opening when the first die segment is in the closed position. A punch is moveably mounted to the base for shifting between a retracted position and an extended position wherein the punch crimps a part positioned within the cavity. A powered actuator is connected to at least the first one of the die segments, and shifts the first die segment between the closed and opened positions such that a part positioned within the cavity can be removed after crimping by shifting of the first die segment to the open position. The forming die is particularly well-suited for crimping electrochemical cells.

Description: CRIMPING DIE EMPLOYING POWERED CHUCK The present invention relates to cπmping dies and the like, and in particular to a cπmping die that utilizes a powered chuck and segmented die to release a formed part Cπmping dies of the present invention are useful for closing and sealing electrochemical cells, particularly small button cells. Vaπous types of metal forming dies have been used in the fabrication of a wide array of parts. One example is an electrochemical battery cell having a two piece cladding that is cπmped together to form the finished battery cell. Known cπmping methods utilize a one piece temale die. A punch dπves the two pieces of the cell into the female die segment, thereby deforming the outer edge of one of the cell pieces, and cπmping the two sections together to form the electrochemical cell. One problem encountered in such an arrangement is that the formed steel part will have some residual stress, causing the part to "spπng" outwardly against the inner sidewalls of the female die segment. The friction generated between the part and the sidewalls of the female die segment can make removal of the formed cell difficult, leading to damage of the cell Although lubπcants may aid removal of the cell to some degree. such lubπcants may lead to contamination of the cell. Even with lubπcation it may not be possible to cπmp the cell as tightly as desired and still permit removal of the cell w ithout damage thereto, particularly for cells with thin sidewalls. such as button an cells A prior art segmented cπmping die is shown in Figures 8 and 9A-9C. As shown in Figures 9A-9C. the pπor art die includes a one-piece base support 101 hav ing a bore 102 through which a lower punch 103 may be moved. Base plate 101 is generallv fixed relative to the other parts Base plate 101 further includes a recess 104 in which a one- piece cπmp die 105 is disposed. Cπmp die 105 also includes a central aperture through which lower punch 103 extends. The die further includes a tapered guide housing 106 disposed in fixed relation on base plate 101 and a top plate 107 mounted atop tapered guide housing 106 Tapered guide housing 106 includes a centrally disposed tapered opening 109 for receiving four segmented dies 108a- 108d As shown in Figure 8 which is a top view of the four segmented dies, the four segmented dies together form annular side walls of the die and define a central opening through which an upper punch L 1 1 and a battery 110 to be cπmped may be moved Top plate 107 also includes a centrally disposed hole of the same diameter for similarly allowing upper punch 1 1 1 and cell 110 to be moved therethrough As shown, the four segmented dies are tapered and allowed to slide vertically along the tapered surface 109 of guide 106 In this matter, as the tour segmented dies 108a-108d move vertically between the upper surface of the one-piece cnmp die 105 and the lower surface of top plate 107, the four segmented dies move radially inward and outw ard to thereby increase/decrease the diameter of the centrally disposed aperture defined by the tour segmented dies 108a- 108d In operation, the die press is positioned with the four segmented dies 108a- 108d in their lowermost position resting upon the upper surface of one-piece cπmp die 105 A battery 110 is placed within aperture 1 12. and upper punch 1 11 is moved vertically downward to push the cell down against the curved portion of cπmp die 105 Once the cell has been cπmped, upper punch 111 is raised and lower punch 103 is moved vertically upward as shown in Figure 9B to push the cπmped battery upward through aperture 1 12 Because of the close tolerances with aperture 1 12 relative to the outer dimensions of the battery, the four segmented dies 108a-108d tend to move upward as the batterv is lifted lower punch 103 As the four segmented dies 108a- 108d are lifted, they w ill mov e iadiallv, outward at the same time until their upper surfaces abut the stops on top plate 107 With the four segmented dies in their uppermost position, the diameter of aperture 1 12 is sufficient to freely remove battery 110 from the die apparatus A problem exists, however, in that some of the segmented dies 108a- 108d mav at times become hung up, as shown in Figure 9C Thus, when the next battery is inserted tor cπmping, the battery may become misaligned and a uniform cπmping of the batterv mav not be obtained A similar problem can occur duπng cπmping. with one segment πsing up independent of the other segments, due to the axial component of the radial stress on the - j - angled surface, and thereby limiting the amount of radial stress that can be applied during cπmping. When closing or sealing electrochemical cells, the above problems can result in damage to the cells, increased manufactuπng costs, reduced shelf life, increased leakage and reduced discharge capacity after storage. This is particularly evident with button cells, which are small in size and mass Reducing the crimping force applied duπng closing or sealing is not an effective solution, since the effectiveness of the cell seal may be sacπficed. Accordingly, an apparatus and method for closing and sealing electrochemical cells that solves the above-identified processing problems and produces a better seal is desirable. We have now found that this may be accomplished by using a segment forming die. having at least one of the die segments opened and closed by a powered actuator, to cπmp the open end of the cell container closed. One aspect of the present invention is to provide a forming die including a base and at least two die segments. At least a first one of the die segments is moveably mounted to the base for shifting between closed and opened positions. The die segments together define a cavity having an opening when the first die segment is in the closed position A punch is moveably mounted to the base for shifting between a retracted position and an extended position wherein the punch cπmps a part positioned withm the cavitv A powered actuator is connected to at least the first one of the die segments, and shifts the first die segment between the closed and opened positions such that a part positioned withm the cavity can be removed after cπmping by shifting of the first die segment to the open position. Another aspect of the present invention is a forming die including a base and a pneumatic chuck. The pneumatic chuck has at least two powered jaws, each ha ing a die segment mounted thereon, actuated by pneumatic pressure. Yet another aspect of the present invention is a forming die including a base and a fluid actuated clamp In a prefeπed embodiment, the powered actuator comprises a flexible member, within a chamber, that moves in response to changes of pressure withm the chamber to move the die segments. The present invention will be further understood by reference to the drawings, in which. Figure 1 is a partially fragmentary, front elevational view of a cπmping die embodying the present invention, compπsing an upper punch, and a lower segmented die utilizing an air chuck to release a cπmped part: Figure 2 is a cross-sectional view of the cπmping die of Figure 1 , taken along the Figure 3 is a cross-sectional view of the cπmping die of Figure 1, taken along the Figure 4 is a top elevational view of the die segments; Figure 5 is a partially fragmentary, front elevational view of the die segment of Figure 4. taken along the line IV-IV; Figure 6 is a partially fragmentary, cross-sectional view illustrating the cπmping of a part; Figure 7 is a partially fragmentary, cross-sectional view illustrating the cπmping of a part. Figure 8 is a partially schematic top plan view of a pπor art segmented cπmping Figure 9A is a partially fragmentary, cross-sectional view of the pπor art cπmping die of Figure 8 taken along the line IXA-IXA; Figure 9B is a partially fragmentary, cross-sectional view of the pπor art segment die of Figure 9A showing the segmented die in the open position; Figure 9C is a partially fragmentary, cross-sectional view of the pπor art cπmping die of Figures 8 and 9 showing the upper punch in the raised position: Figure 10 is a schematic drawing of a membrane type air chuck For purposes of descπption herein, the terms " uppei . " "lowei ." "" πght. " " left. " "rear. "" "front. " "vertical. " "" honzontal. " and derivatives thereof shall relate to the invention as oπented in Figure 1 However, it is to be understood that the invention may assume v aπous alternative oπentations and step sequences, except w ere expressly specified to the contrary It is also to be understood that the specific devices and processes illustrated in the attached drawings and descπbed in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteπstics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise The reference numeral 1 (Figure 1 ) generally designates a forming die embodying the present invention, which is particularly designed for forming electrochemical cells and the like, as by cπmping. In the illustrated example, the forming die includes at least two die segments 2. at least a first one of which is movably mounted to a base or support structure 3 for shifting between closed and open positions. In the illustrated example, the die segments 2 are mounted to the ja s 5 of a pneumatic, or "air " chuck 4 The die segments 2 together define a die cavity 6 (see also Figures 4-7) having an opening 7 when the die segments 2 aie in the closed position. A punch 8 is moveably mounted to the base 3 for shifting between a retracted position and an extended position In the extended position the punch 8 forces a part, such as a miniature electrochemical cell 9. into the wall-, of cavity 6 thereby cπmping the cell. A pow ered actuator is connected to at least one ot the die segments 2. and shifts the die segment 2 between the closed and opened positions. such that the electrochemical cell 9 positioned within the cav ity 6 can be removed aftei cπmping by shifting ot the die segments 2 to the opened position. With reference to Figures 1. 2 and 3. the base 3 generally includes a v ertical plate 10. and upper and lower honzontal plates 1 1 and 12. respectively. A beaπng plate 13 i ihdably mounted to the vertical plate 10 by a pair of vertical rods 14 and pillow blocks 1 5 A punch holder assembly 16 is secured to the beaπng plate 13 by conventional fasteners oi the like (not shown). The punch holder assembly 16 securely holds the punch 8 in alignment with the lower cavity 6 formed by the die segments 2 A rod 17 is secured to the punch holder assembly 16 Rod 17 is attached to an electnc ser o, hydraulic dπver. or other powered actuator (not shown) having sufficient force to form the part 9 in the die cavity 6 The electrochemical cells 9 are transferred to the die and cπmped cells 9 are removed from the die after the forming operation. Any suitable mechanism, such as an index wheel, can be used for this purpose The pneumatic chuck 4 is securely supported on a honzontal plate 19 of the base 3 by a support assembly 18 A lower punch 20 is positioned below the pneumatic chuck 4. Punch 20 is shdably supported in alignment with the cavity 6 by a punch holder assembly 21. A spπng 22 is supported by a stop block 23, and biases the lower punch 20 upwardly into the die cavity 6. An adjustable stop 24 is threadably received within the stop block 23, and limits the downward travel of the lower punch 20. As discussed in more detail below, spπng 22 is relatively light weight, and lifts the formed electrochemical cell upwardly upon shifting of the die segments 2 to the opened, released position. With further reference to Figures 4 and 5, each die segment 2 is made of a suitable hardened tool steel, and includes a plurality of openings 25 to secure the die segment 2 to the jaws 5 of the pneumatic chuck 4 Each die segment 2 includes a sidewall 26 that is radiused, such that the die segments 2 together form a cylindπcal die cavity 6 The upper portion 28 ot the sidewall 26 is generally parallel to a vertical axis, and the lower portion 29 of the sidew all curves inwardly at radius 27. With further reference to Figures 6 and 7. a standard electrochemical cell 9 includes a first metal casing portion 30 (also known as the "can") having a shape similar to an inverted cup. The electrochemical cell 9 also includes a second metal casing part 31 (also known as the ' " anode cup") that is also generally cup shaped. The part 31 has a slightly smaller diameter than part 30. such that part 31 fits inside part 30 A seal 34 fits between parts 30 and 31 and prevents electncal conduction between parts 30 and 31 The internal components 32 of the cell 9 are sandwiched between the first and second parts 30 and 31. Duπng operation, an uncπmped electrochemical cell 9 is shifted into position at the upper portion of the die cavity 6. The electrochemical cell 9 is placed on the low er punch 20. which is in its uppermost position due to the upward bias of spπng 22. The die segments are shifted into the extended, or closed, position πy actuation of the pneumatic chuck 4. The upper punch 8 is then shifted downwardly by actuation of the electrochemical servo (not shown). As the upper punch 8 shifts downw ardly, the uncπmped electrochemical cell 9 is pushed downwardly w ith the die cavity 6 until the electrochemical cell 9 is cπmped on the radiused portion 27 of the die cavity 6. The die segments 2 are then shifted outwardly by actuation of the pneumatic chuck 4 into the undamped, or open position. The powered ram and upper punch S are then shifted upwardly, with the lower punch 20 holding the cπmped cell 9 against the upper punch S The die segments 2 are then shifted into the extended, or closed, position; the finished, cπmped cell 9 is removed; and a new. uncπmped cell 9 is brought into the die. Alternatively, the die segments 2 could be in the open position when cell 9 is pushed into the die cavity and then closed to cπmp the cell. However, this may leave undesirable marks, corresponding to the parting lines of die segments 2. on the cπmped surface of cell 9 In the illustrated example descπbed above, the die segments 2 are mounted to a pneumatic chuck 4. A preteπed pneumatic chuck is a fiv e-inch diaphragm chuck av ailable from Northfield Precision Instrument Corporation of Island Park. New York. A membrane air chuck 40 is shown schematically in Figure 10. Penpheral portions 41 of the jaw s 5 ai e mounted to a penpheral base 42 via a flexible diaphragm 43 When compressed air is introduced into air passageway 45. a resulting force is applied to the lower side 44 of the j aws 5 by the chuck. This causes jaws 5 and attached die segments 2 to pivot upward and outward to the open position. When compressed air is introduced into air passageway 46 the laws 5 are moved to the closed position. Other pneumatic chucks may also be used For example, a six- ch air chuck, model no. 6- 120NR-3. available from MicroCentnc Corporation of Plamview. New York, may be used. As illustrated in Figure 3. ]aw s 5 ol this type of chuck are mechanically dπven radially inward and outward, to the closed and opened positions respectivelv . It is anticipated that other types of powered actuators couid be connected to one or more of the die segments 2 to permit shifting of the die segments for release of the cπmped cell For example, the die segments 2 could be movably mounted to the base by a conventional slide arrangement, with an electrochemical, pneumatic, or other powered actuator connected to the movable die segment! s) for shifting between closed and open positions. Die segments 2 may be mounted to |aw s 5 by any suitable means, such as bolting, screwing, w elding, clamping, pinning, gluing and so on; or die segments 2 may be an integral part of laws 5. It is also anticipated that other types of flexible members could be used instead of a flexible diaphragm. For example, each die segment could be biased by one or more separate flexible members. Because die segments 2 are fastened to jaws 5, undesirable ertical movement of die segments 2 is prevented. The forming die of the present invention facilitates removal of the finished electrochemical cell, without damage of the cell, or contamination by lubπcants or the like. Furthermore, the diameter of the cyhndπcal die cavity 6 can be made smaller relative to the part being formed, thereby permitting a tighter cπmp of the electrochemical cell 9, yet still permitting removal of the cπmped cell without damage. In the foregoing descπption. it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications aie to be considered as included in the following claims, unless these claims by their language expressly state otherw ise

Claims: CLAIMS: 1 A forming die, comprising a base; at least two die segments, at least a first one of which is movably mounted to said base for shifting between closed and open positions, said die segments togethei defining a cavity hav ing an opening when said first die segment is in said closed position. a punch movably mounted to said base for shifting between a retracted position and an extended position wherein said punch pushes against a part positioned with said cavity, thereby causing the part to be cπmped: and a powered actuator connected to at least the first one of said die segments and shifting said first die segment between said closed and open positions such that a part positioned withm said cavity can be removed after cnmpmg by shifting of the first die segment to the open position. 2. A forming die according to claim 1 , wherein said powered actuator compπses a pneumatic chuck having at least two powered jaws actuated by pneumatic pressure, each of said powered jaws having one of said die segments mounted thereon 3 A forming die according to claim 2. wherein said pneumatic chuck is a three-jaw air chuck 4 A forming die according to any preceding claim, w herein said poweied actuator includes a flexible member and a chamber on a first side of said member, said die segments mounted on a second side of said member, said member flexing upon pressuπzation of said chamber to shift said die segments to said open position 5 A forming die according to claim 1. w herein said powered actuator compπses a fluid actuated clamp. 6 A forming die according to claim 5. wherein said fluid actuated clamp includes 3 j aws, said die pieces mounted on said jaws 7 A forming die according to claim 5. wherein said fluid actuated clamp furthei includes a chamber and a flexible member communicating withm said chamber, such that said clamp moves in response to changes of pressure w lthm said chamber 8. A forming die according to claim 4 or claim 7. w herein said flexible member is configured to rotate said die pieces upon pressunzation of said chamber 9 A forming die according to claim 4 or claim 7. wherein said flexible member is a diaphragm. 10. A forming die according to claim 1. herein said die cavity has a sidewall surface defining a generally cyhndπcal shape. 11. A forming die according to claim 10. wherein said generally cyhndncal shape compπses first and second open ends and an inwardly tapeπng portion adjacent said second open end. 12 A forming die according to claim 1 1. wherein said punch compnses a first punch and said forming die has a second punch. 13. A forming die according to claim 12. wherein said first punch enters said first open end of said die cavity to form a part positioned therein and said second punch shifts into said second open end of said die cavity to eject a formed part 14 A forming die according to claim 12 or claim 13. wherein said power actuator is connected to said first punch for shifting said first punch between extended and retracted positions 15. A forming die according to claim 2 oi claim 6. wherein said ]aw s aie mov ably interconnected. 16. A method of sealing the casing of an electrochemical cell, compnsing the steps' (a) assembling a first metal casing portion and a second metal casing portion inside an open end of said first metal casing portion, with a seal disposed between said first and second metal casing portions, and (b) cnmping said first metal casing portion against said seal and said second metal casing portion with a forming die according to any preceding claim 17 A method of sealing the casing of an electrochemical cell according to claim 16, wherein said first metal casing portion is a can and said second metal casing portion is a cup

Inventors: PIANTONI RAYMOND W, RAY ROBERT E JR, PIANTONI, RAYMOND, W., RAY, ROBERT, E., JR.
Applicants: EVEREADY BATTERY INC, EVEREADY BATTERY COMPANY, INC.
Application year: 2001
Main classification: B23P11
IPC codes: B21D39, H01M2, H01M6