Abstract: A fusion welding system utilizing a radiant energy heat source such as a laser or electron-beam. The system uses a weld or filler wire having a non-round cross-section shape oriented such that the minor axis of the filler wire is aligned to intersect or nearly intersect the weld bead line. The filler wire cross-sectional shape provides enhanced surface interaction with the radiant energy heat source and possesses mechanical properties enabling more precise positioning of the wire relative to the radiant energy heat source and the weld area.

Abstract: Interconnection assemblies and methods are provided. An interconnection assembly includes a first cell tab constructed of a first metal, and a second cell tab disposed against the first cell tab. The second cell tab is constructed of a second metal having a hardness greater than the first metal. The assembly further includes an interconnect member disposed against the second cell tab. The assembly further includes a weld assisting layer disposed against the first cell tab such that the first and second cell tabs are disposed between the weld assisting layer and the interconnect member.

Abstract: Battery modules having interconnect members are provided. An interconnect member includes a first plate portion having a first thickness. The interconnect member further includes a second plate portion having a second thickness equal to the first thickness. The second plate portion extends generally parallel to the first plate portion. The interconnect member further includes a first vibration dampening portion coupled to the first and second plate portions. The first vibration dampening portion has a third thickness greater than the first thickness, such that vibrations induced on the first plate portion are attenuated when a portion of the vibrations pass through the first vibration dampening portion to the second plate portion.

Abstract: A battery module and methods for bonding cell terminals of battery cells together are provided. The battery module includes a first battery cell having a first cell terminal, and a second battery cell having a second cell terminal. The battery module further includes an exothermal reactive layer having first and second sides. The first and second sides are disposed adjacent to the first and second cell terminals, respectively. The exothermal reactive layer is configured to ignite to form a bonding joint between the first and second cell terminals in response to a laser beam contacting at least a portion of the exothermal reactive layer.

Abstract: Interconnection assemblies and methods are provided. An interconnection assembly includes a first cell tab constructed of a first metal, and a second cell tab disposed against the first cell tab. The second cell tab is constructed of a second metal having a hardness greater than the first metal. The assembly further includes an interconnect member disposed against the second cell tab. The assembly further includes a weld assisting layer disposed against the first cell tab such that the first and second cell tabs are disposed between the weld assisting layer and the interconnect member.

Abstract: Interconnection assemblies and methods are provided. An interconnection assembly includes a first cell tab constructed of a first metal, and a second cell tab disposed against the first cell tab. The second cell tab is constructed of a second metal having a hardness greater than the first metal. The assembly further includes an interconnect member disposed against the second cell tab. The assembly further includes a weld assisting layer disposed against the first cell tab such that the first and second cell tabs are disposed between the weld assisting layer and the interconnect member.

Abstract: An ultrasonic welding machine and method are provided. The machine includes a base portion having a first aperture that defines first internal threads. The machine further includes an electrically non-conductive member disposed on the base portion having a second aperture that is aligned with the first aperture. The machine further includes an anvil portion disposed on the electrically non-conductive member having a third aperture that is aligned with the second aperture. The machine further includes a first bolt disposed through the third aperture and the second aperture that is threadably received in the first internal threads, and the first bolt and the anvil portion are electrically isolated from the base portion.

Abstract: An ultrasonic welding machine and method are provided. The machine includes an ultrasonic welding horn operably coupled to a housing. The machine further includes an anvil operably coupled to the housing. The machine further includes a removable collar assembly that is coupled around a portion of an outer surface of the ultrasonic welding horn. The removable collar assembly has at least first and second set screws that contact the housing such that when at least one of the first and second set screws are moved inwardly toward the housing, the removable collar assembly rotates the ultrasonic welding horn to align the ultrasonic welding horn relative to the anvil.

Abstract: A vehicular collision protection device is provided. The device includes a plastic shaft having a first end portion and a second end portion and extending along a longitudinal axis. The first end portion is received in a vehicle hitch receiver. The plastic shaft has a plurality of apertures extending therethrough and are spaced apart from one another. At least one of the plurality of apertures receives a locking pin therethrough that removably couples the plastic shaft to the vehicle hitch receiver. The device further includes a plate member coupled to the second end portion of the plastic shaft.

Abstract: A system and a method for determining whether an ultrasonic horn is aligned with an anvil of an ultrasonic welding system are provided. The first and second accelerometer sensors generate first and second signals indicative of first and second accelerations of first and second positions on a bracket coupled to the anvil when the ultrasonic horn is vibrating and contacting the anvil. The system further includes a microprocessor that receives the first and second signals. The microprocessor determines a difference between an amplitude of the first signal at a first time and an amplitude of the second signal at the first time. The microprocessor stores a first identifier value in a memory device indicating that the ultrasonic horn is aligned with the anvil if the difference between the amplitude of the first signal and the amplitude of the second signal is less than or equal to a threshold value.

Abstract: An ultrasonic welding assembly having an ultrasonic horn and an anvil having first, second, and third plate portions is provided. The third plate portion is coupled between the first and second plate portions. The first plate portion has a first knurled region on a first side disposed proximate to the ultrasonic horn, and the second plate portion has a second knurled region on a second side. The third plate portion has a first aperture extending therethrough. The assembly includes a bracket that receives the second side of the anvil for holding the anvil thereon. The bracket has a second aperture that aligns with the first aperture, such that a coupling member extending through the first and second apertures removably couples the anvil to the bracket.

Abstract: Interconnection assemblies and methods are provided. An interconnection assembly includes a first cell tab constructed of a first metal, and a second cell tab disposed against the first cell tab. The second cell tab is constructed of a second metal having a hardness greater than the first metal. The assembly further includes an interconnect member disposed against the second cell tab. The assembly further includes a weld assisting layer disposed against the first cell tab such that the first and second cell tabs are disposed between the weld assisting layer and the interconnect member.

Abstract: An ultrasonic welding machine and method are provided. The machine includes a base portion having a first aperture that defines first internal threads. The machine further includes an electrically non-conductive member disposed on the base portion having a second aperture that is aligned with the first aperture. The machine further includes an anvil portion disposed on the electrically non-conductive member having a third aperture that is aligned with the second aperture. The machine further includes a first bolt disposed through the third aperture and the second aperture that is threadably received in the first internal threads, and the first bolt and the anvil portion are electrically isolated from the base portion.

Abstract: An ultrasonic welding machine and method are provided. The machine includes an ultrasonic welding horn operably coupled to a housing. The machine further includes an anvil operably coupled to the housing. The machine further includes a removable collar assembly that is coupled around a portion of an outer surface of the ultrasonic welding horn. The removable collar assembly has at least first and second set screws that contact the housing such that when at least one of the first and second set screws are moved inwardly toward the housing, the removable collar assembly rotates the ultrasonic welding horn to align the ultrasonic welding horn relative to the anvil.

Abstract: Battery modules having interconnect members are provided. An interconnect member includes a first plate portion having a first thickness. The interconnect member further includes a second plate portion having a second thickness equal to the first thickness. The second plate portion extends generally parallel to the first plate portion. The interconnect member further includes a first vibration dampening portion coupled to the first and second plate portions. The first vibration dampening portion has a third thickness greater than the first thickness, such that vibrations induced on the first plate portion are attenuated when a portion of the vibrations pass through the first vibration dampening portion to the second plate portion.

Abstract: A system and a method for determining whether an ultrasonic horn is aligned with an anvil of an ultrasonic welding system are provided. The first and second accelerometer sensors generate first and second signals indicative of first and second accelerations of first and second positions on a bracket coupled to the anvil when the ultrasonic horn is vibrating and contacting the anvil. The system further includes a microprocessor that receives the first and second signals. The microprocessor determines a difference between an amplitude of the first signal at a first time and an amplitude of the second signal at the first time. The microprocessor stores a first identifier value in a memory device indicating that the ultrasonic horn is aligned with the anvil if the difference between the amplitude of the first signal and the amplitude of the second signal is less than or equal to a threshold value.

Abstract: A battery module and methods for bonding cell terminals of battery cells together are provided. The battery module includes a first battery cell having a first cell terminal, and a second battery cell having a second cell terminal. The battery module further includes an exothermal reactive layer having first and second sides. The first and second sides are disposed adjacent to the first and second cell terminals, respectively. The exothermal reactive layer is configured to ignite to form a bonding joint between the first and second cell terminals in response to a laser beam contacting at least a portion of the exothermal reactive layer.

Abstract: A battery module and methods for bonding a cell terminal of a battery to an interconnect member are provided. The battery module includes a battery cell having a cell terminal, and an exothermal reactive layer having first and second sides. The first side is disposed adjacent to the cell terminal. The module further includes an interconnect member disposed adjacent to the second side of the exothermal reactive layer. The exothermal reactive layer is ignited to form a bonding joint between the interconnect member and the cell terminal in response to a laser beam contacting at least a portion of the exothermal reactive layer.

Abstract: An ultrasonic welding assembly having an ultrasonic horn and an anvil having first, second, and third plate portions is provided. The third plate portion is coupled between the first and second plate portions. The first plate portion has a first knurled region on a first side disposed proximate to the ultrasonic horn, and the second plate portion has a second knurled region on a second side. The third plate portion has a first aperture extending therethrough. The assembly includes a bracket that receives the second side of the anvil for holding the anvil thereon. The bracket has a second aperture that aligns with the first aperture, such that a coupling member extending through the first and second apertures removably couples the anvil to the bracket.