Pouch Cell Wedge Recess Forming Process

The single deep draw process is segmented into two sequential drawing operations: a first draw that forms an intermediate shape with rounded corners, and a second draw that achieves the final deep configuration. This segmentation allows the metal laminated film to be deformed in controlled stages, preventing corner tearing that would occur in a single deep draw operation.

The first draw operation performs a preliminary deformation of the metal laminated film to create an intermediate housing shape with rounded corners before the second draw is applied. This preliminary action prepares the material by reducing corner sharpness and distributing stress more evenly, enabling the subsequent second draw to achieve greater depth without causing material failure.

The total deformation required for deep housing formation is segmented into two drawing operations, each applying a portion of the total stress. The first draw applies initial deformation stress, and the second draw applies additional stress to achieve the final depth. This segmentation keeps the stress in each individual operation below the material's failure threshold while achieving the cumulative effect needed for high power storage capacity.

The drawing process parameters are changed between two operations: the first draw uses parameters optimized for initial deformation with larger corner radii, and the second draw uses parameters optimized for final depth achievement. By changing the drawing parameters and performing multiple passes, the material can accommodate greater overall deformation without exceeding stress limits in any single operation.

The conventional single-step drawing process is replaced with a two-step sequential drawing process. The first draw creates an intermediate housing shape, and the second draw achieves the final deep configuration. While this increases process complexity compared to a single draw operation, it enables draw depths far exceeding the 6-8 mm limit of conventional single-pass processes.

The forming process uses periodic action by applying drawing operations in distinct sequential stages rather than continuously. The first draw operation completes its deformation, then the second draw operation is applied to achieve further depth. This periodic, multi-stage approach allows the material to recover and redistribute stresses between stages, enabling greater total draw depth than a continuous single-pass process.