Multistage plunger press systems and methods with interlocking fingers for forming battery cell tabs

A metalworking system for forming a first set of metallic workpieces and a second set of multiple metallic workpieces, the metalworking system comprising:

• a plunger fixture configured to mount adjacent the first set of metallic workpieces and the second set of metallic workpieces;
• a plunger head movably mounted to the plunger fixture and configured to transition between a deactivated position and an activated position;
• a first set of plunger fingers mounted to the plunger head and configured to move in a first bend direction to thereby press against and bend the first set of metallic workpieces to a first bend angle;
• and
• a second set of plunger fingers mounted to the plunger head and configured to move in a second bend direction, opposite the first bend direction, to thereby press against and bend the second set of metallic workpieces to a second bend angle, wherein a first length of each plunger finger in the first set of plunger fingers is shorter than a second length of each plunger finger in the second set of plunger fingers such that the first set of plunger fingers bends the first set of metallic workpieces a first bend distance and the second set of plunger fingers bends the second set of metallic workpieces a second bend distance greater than the first bend distance,
• wherein the plunger head is configured to move to the activated position, in tandem with the first and second sets of plunger fingers bending the first set of metallic workpieces and the second set of metallic workpieces to the first bend angle and second bend angle, respectively, to thereby cause the first set of plunger fingers and second set of plunger fingers to bend the first set of metallic workpieces and the second set of metallic workpieces to a third bend angle and a fourth bend angle, respectively.

A method for forming a first metallic workpiece and a second metallic workpiece, the method comprising:

• mounting a plunger fixture of a plunger assembly adjacent the first metallic workpiece and the second metallic workpiece, the plunger assembly including a plunger head movably mounted to the plunger fixture, and a first set of plunger fingers and a second set of plunger fingers mounted to the plunger head, the plunger head including a first plunger plate slidably mounted to a second plunger plate, and a spring member spring-mounting the first plunger plate and the second plunger plate to the plunger fixture;
• moving the first set of plunger fingers in a first bend direction to thereby press against and bend the first metallic workpiece to a first bend angle;
• moving the second set of plunger fingers in a second bend direction, opposite the first bend direction, to thereby press against and bend the second metallic workpiece to a second bend angle;
• and
• moving the plunger head, in tandem with the first set of plunger fingers and the second set of plunger fingers bending the first metallic workpiece and the second metallic workpiece the first bend angle and second bend angle, respectively, from a deactivated position to an activated position to thereby cause the first set of plunger fingers and the second set of plunger fingers to further bend the first metallic workpiece and the second metallic workpiece a third bend angle and a fourth bend angle, respectively.