Multistage plunger systems and methods for forming battery cell tabs

Patent metadata

Field	Value
Publication number	US-11804639-B2
Application number	US-202016937018-A
Country	US
Kind code	B2
Filing date	Jul 23, 2020
Priority date	Jul 23, 2020
Publication date	Oct 31, 2023
Grant date	Oct 31, 2023

Abstract

Presented are metalworking systems for forming metallic workpieces, methods for making/operating such metalworking systems, and battery module cell tabs bent by a multistage cluster-and-bend press. A metalworking system includes a grouping tool and a contouring tool that both align adjacent a workpiece support structure, such as a base plate of a battery module housing buttressing a stack of battery pouch cells. The grouping tool, which may include a first reciprocating plunger or plunger head, presses together a stack of metallic workpieces to thereby form a workpiece set having a first bend profile and a first length. The contouring tool, which may include a second reciprocating plunger or a pair of plunger fingers mounted on the plunger head, is attached to the grouping tool and bends the workpiece set to a second bend profile, distinct from the first bend profile, and a second set length, shorter than the first set length.

First claim

What is claimed:

1. A metalworking system for forming first and second metallic workpieces aligned on a support structure, the metalworking system comprising:
a grouping tool configured to align adjacent the support structure and press together the first and second metallic workpieces to thereby form a workpiece set having a first bend profile and a first set length; and
a contouring tool attached to the grouping tool and configured to bend the workpiece set to a second bend profile, distinct from the first bend profile, and a second set length, shorter than the first set length;
wherein the grouping tool includes a first plunger with a first plunger body having a first die cavity recessed into a first contact face of the first plunger body, the first contact face being configured to simultaneously contact the first and second metallic workpieces.

2. The metalworking system of claim 1 , wherein the first die cavity includes first and second cavity surfaces configured to simultaneously press against and bend towards each other the first and second metallic workpieces, respectively, to thereby form the workpiece set.

3. The metalworking system of claim 2 , wherein the first die cavity further includes a first elongated slot segregating the first and second cavity surfaces and configured to slidably receive therein distal ends of the first and second metallic workpieces.

4. The metalworking system of claim 2 , wherein the contouring tool includes a second plunger movably coupled to the first plunger, the second plunger including a second plunger body having a second die cavity recessed into a second contact face of the second plunger body, the second contact face being configured to simultaneously contact the first and second metallic workpieces of the workpiece set.

5. The metalworking system of claim 4 , wherein the second die cavity includes third and fourth cavity surfaces configured to simultaneously press against and bend the workpiece set and thereby impart the second bend profile with the second set length.

6. The metalworking system of claim 5 , wherein the second die cavity further includes a second elongated slot segregating the third and fourth cavity surfaces and configured to slidably receive therein distal ends of the first and second metallic workpieces.

7. The metalworking system of claim 4 , wherein the first plunger includes a plunger passage extending through the first plunger body, and the second plunger is slidably mounted to the first plunger with the second plunger body moving within the plunger passage such that the second plunger bends the first and second metallic workpieces in tandem with the first plunger bending the first and second metallic workpieces.

8. The metalworking system of claim 1 , further comprising a plunger fixture configured to mount to the support structure adjacent the first and second metallic workpieces and align the grouping and contouring tools with the first and second metallic workpieces.

9. The metalworking system of claim 8 , wherein the plunger fixture includes a comb platen with first and second elongated slots each configured to receive therethrough a respective one of the first and second metallic workpieces.

10. The metalworking system of claim 1 , wherein the grouping tool includes a plunger head configured to movably mount adjacent the support structure, the plunger head including first and second contact surfaces configured to simultaneously bend the first and second metallic workpieces, respectively, towards each other to thereby form the workpiece set.

11. A method for forming first and second metallic workpieces aligned_on a support structure, the method comprising:
aligning, adjacent the support structure, a grouping tool and a contouring tool attached to the grouping tool;
plunging the grouping tool towards the support structure to press together the first and second metallic workpieces to thereby form a workpiece set having a first bend profile and a first set length; and
activating the contouring tool to thereby bend the workpiece set to a second bend profile, distinct from the first bend profile, with a second set length, shorter than the first set length;
wherein the grouping tool includes a first plunger with a first plunger body having a first die cavity recessed into a first contact face of the first plunger body, and wherein the first die cavity includes first and second cavity surfaces configured to simultaneously bend towards each other the first and second metallic workpieces, respectively, to thereby form the workpiece set.

12. The method of claim 11 , wherein the first die cavity further includes a first elongated slot segregating the first and second cavity surfaces and configured to slidably receive therein distal ends of the first and second metallic workpieces.

13. The method of claim 11 , wherein the contouring tool includes a second plunger movably coupled to the first plunger, the second plunger including a second plunger body having a second die cavity recessed into a second contact face of the second plunger body, and wherein the second die cavity includes third and fourth cavity surfaces configured to simultaneously bend the workpiece set and thereby impart the second bend profile with the second set length.

14. The method of claim 13 , wherein the second die cavity further includes a second elongated slot segregating the third and fourth cavity surfaces and configured to slidably receive therein distal ends of the first and second metallic workpieces.

15. The method of claim 13 , wherein the first plunger includes a plunger passage extending through the first plunger body, and the second plunger is slidably mounted to the first plunger with the second plunger body moving within the plunger passage such that the second plunger bends the first and second metallic workpieces in tandem with the first plunger bending the first and second metallic workpieces.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Dietze Robert H

Classifications

• H01M50/553 Primary

  Terminals adapted for prismatic, pouch or rectangular cells · CPC title

• B21D7/08

  by passing between rollers or through a curved die · CPC title

• B21D11/10

  Bending specially adapted to produce specific articles, e.g. leaf springs {(making or bending leaf springs B21D53/886)} · CPC title

• B21D31/005

  Incremental shaping or bending, e.g. stepwise moving a shaping tool along the surface of the workpiece (B21D22/14 takes precedence) · CPC title

• B21D39/02

  of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder · CPC title