US 12,136,747 B2
Method of making a battery cell including clamping, tapering, trimming and ultrasonic welding of electrode foils
Wayne W. Cai, Troy, MI (US); Thomas Alumoottil, Carrollton, TX (US); Jennifer T. Bracey, Holly, MI (US); Teresa J. Rinker, Royal Oak, MI (US); and Cammi L. Siu, Macomb, MI (US)
Assigned to GM Global Technology Operations LLC, Detroit, MI (US)
Filed by GM GLOBAL TECHNOLOGY OPERATIONS LLC, Detroit, MI (US)
Filed on Jul. 20, 2022, as Appl. No. 17/868,887.
Prior Publication US 2024/0030564 A1, Jan. 25, 2024
Int. Cl. H01M 50/536 (2021.01); B23K 20/10 (2006.01); B23K 101/36 (2006.01)
CPC H01M 50/536 (2021.01) [B23K 20/10 (2013.01); B23K 2101/36 (2018.08)] 20 Claims
OG exemplary drawing
 
1. A method for manufacturing a battery cell using a workstation, the battery cell having a plurality of electrode foils protruding from a cell body, the method comprising:
positioning the cell body in a fixture of the workstation such that distal end sections of the electrode foils extend outward from the fixture;
clamping the distal end sections of the electrode foils between resilient polymer surfaces of a curvilinear guide clamp of the workstation to cause the distal end sections of the electrode foils to taper into an electrode foil stack;
translating the curvilinear guide clamp by a predetermined distance toward the fixture to displace the distal end sections of the electrode foils by the predetermined distance;
trimming a portion of the distal end sections of the electrode foils by using a trim tool of the workstation;
positioning a sonotrode and an anvil of the workstation adjacent to opposite surfaces of the electrode foil stack; and
ultrasonically welding the electrode foil stack to a conductive lead tab of the battery cell using the sonotrode to form a welded joint within the battery cell.