Abstract: A process for making a hollow electrical coil for an electric motor includes forming a sacrificial insert material into a coil shaped insert. The coil shaped insert is placed into a copper plating bath and a copper plated coil shaped member is removed from the copper plating bath. The sacrificial material is removed from within the copper plated coil shaped member to create a hollow passage through a hollow copper coil shaped member. An exterior of the hollow copper coil shaped member is coated with an insulating adhesive material and the copper coil shaped member is compressed until the insulating adhesive material is set.

Abstract: A vehicle braking component having a composite structure includes a brake core comprising an aluminum alloy, the brake core defining a core surface, a thermal barrier layer comprising a thermally insulating material, and an adhesion layer between the core surface and the thermal barrier layer to facilitate adhesion between the thermal barrier layer and the brake core. The adhesion layer includes a metal. The vehicle braking component includes a wear-resistant layer on the thermal barrier layer. The wear-resistance layer includes an iron-aluminum-silicon-zirconium alloy and defines a friction surface of the vehicle braking component.

Abstract: A cooling system includes a housing including a base portion with sides and a bottom surface that define a cavity and a cover portion to enclose the base portion and including cooling members attached thereto. A shield is arranged in the cavity. A vertical member is arranged below the shield to define a first fluid chamber between one side of the vertical member and one side of the base portion and a second fluid chamber between an opposite side of the vertical member and another side of the base portion. The electronic components are arranged in the second fluid chamber. Cooling fluid is arranged in the cavity and has a fluid level below at least a portion of the shield. The housing is mounted at an inclined angle relative to horizontal or the housing is mounted parallel to horizontal and the shield is mounted at the inclined angle.

Abstract: A gradient steel includes a first layer, a second layer near a first surface of the first layer, and a third layer near a second surface of the first layer. The first layer includes a first ferrite phase volume. The second and third layers include a second ferrite phase volume greater than the first ferrite phase volume. The gradient steel may also include a fourth layer near the second layer and a fifth layer near the third layer. The fourth and fifth layers may each include a third ferrite phase volume greater than the second ferrite phase volume. The gradient steel may also include a sixth layer near the fourth layer and a seventh layer near the fifth layer. The sixth and seventh layers may each include a fourth ferrite phase volume greater than the third ferrite phase volume.

Abstract: A method of making a battery current collector foil includes heat treating a foil sheet and mechanically roughening the heat treated foil sheet to create a surface roughness of between 2-4 ?m. The heat treating and mechanical roughening of the foil sheet provides improved coating adhesion. One of an anode and cathode coating is then applied to the roughened, heat treated, foil sheet.

Abstract: A cooling system includes a housing configured to enclose an electric vehicle component immersed in cooling fluid and to define a first volume. A variable volume member defines a second volume that varies in response to a first signal. A combined volume is defined by the first volume and the second volume. Heat causes the cooling fluid to transition between a liquid state and a vapor state in the combined volume. A pressure sensor is configured to sense a pressure in the combined volume. A condenser is configured to cause the cooling fluid to transition from the vapor state back to the liquid state. A controller includes a volume adjustment module configured to generate the first signal to vary the second volume of the variable volume member to adjust the combined volume in response to the pressure and a first temperature of the electric vehicle component.

Abstract: A system configured to roll a metal into a foil. The system includes rollers spaced apart to receive the metal therebetween. The rollers are configured to press against the metal to roll the metal into the foil. A cooling sub-system is configured to cool the rollers with a coolant, thereby cooling the foil in contact with the rollers.

Abstract: A method of preparing a metal sheet includes extruding a component along an extrusion axis. The component has a wall at least partially defining an interior region. The component includes a metal. The method further includes unfurling the wall to form a sheet precursor. The sheet precursor has a first thickness and a first transverse dimension. The method further includes rolling the sheet precursor along a rolling axis to form the metal sheet. The metal sheet has a second thickness perpendicular to the rolling axis. The second thickness is less than the first thickness. The second transverse dimension is parallel to the rolling axis. The second transverse dimension is greater than the first transverse dimension. In certain aspects, the metal includes lithium and the metal sheet is a lithium metal electrode.

Abstract: An enclosure for a prismatic battery cell includes an enclosure body including sides, a lid portion, and a bottom portion. The enclosure body is made of steel. A layer is arranged on the enclosure body and includes a material having a higher thermal conductivity than the steel. The layer includes a coating layer or a clad layer.

Abstract: A method of manufacturing a brake rotor or brake drum having a composite structure includes casting an aluminum alloy to form a core of the brake rotor or brake drum, the core defining a core surface, depositing a high entropy alloy or yttrium stabilized zirconia on the core surface to form a thermal barrier layer on the core surface, and depositing an iron-aluminum-silicon-zirconium alloy on the thermal barrier layer to form a wear-resistant layer on the thermal barrier layer, the wear-resistant layer defining a friction surface of the brake rotor or brake drum.

Abstract: A brake drum having a composite structure includes a cylindrical body defining an inner friction surface and an outer surface. The cylindrical body includes a drum core comprising an Al—Si alloy, the drum core including an inner surface, and an outer surface of the drum core defining the outer surface of cylindrical body. The cylindrical body includes a thermal barrier layer comprising a thermally insulating material on the inner surface of the drum core, and a wear-resistant layer comprising an Fe—Al—Si—Zr alloy on the inner surface of the drum core over the thermal barrier layer, the wear-resistant layer defining the inner friction surface of the cylindrical body.

Abstract: A method for using idle computing power of an electric vehicle includes receiving computing tasks while the electric vehicle is electrically connected to a charging infrastructure, accepting to perform the computing tasks while the electric vehicle is electrically connected to the charging infrastructure, and in response to accepting to perform the computing tasks, performing the computing tasks while the electric vehicle is electrically connected to the charging infrastructure.

Abstract: A battery module/pack includes M prismatic battery cells each including a battery cell core. N barrier material layers are arranged between adjacent ones of the M prismatic battery cells, where M and N are integers greater than one. A first end plate includes a flat plate with a raised portion contacting a first side of a first one of the M prismatic battery cells. A second end plate includes a flat plate with a raised portion contacting a first side of a last one of the M prismatic battery cells. The raised portion of the first end plate is smaller in length and width than the first side of the first one of the M prismatic battery cells. The raised portion of the second end plate is smaller in length and width than the first side of the last one of the M prismatic battery cells.

Abstract: A cover panel includes a formed first metal sheet having a plurality of spaced protrusions formed therein. A plurality of sound deadening pads are applied to the formed first metal sheet. A second metal sheet is secured to the formed first metal sheet.

Abstract: A passive cooling system for battery cells includes a housing defining a cavity with a plurality of battery cells disposed in the cavity. Each of the battery cells is surrounded by a porous media and a phase change material is disposed within spaces defined by the porous media. A cold plate is disposed at a top of the cavity to cool the phase change material that is vaporized and change the vapor to a liquid.

Abstract: Presented are battery assemblies containing long prismatic cells with interleaved gas manifolds and electrical busbars, methods for making/using such battery assemblies, and vehicles equipped with such battery assemblies. A prismatic battery assembly includes multiple stacks of prismatic battery cells that are located inside of and extend longitudinally across a rigid and insulated assembly housing. Each battery cell includes a prism-shaped cell can that contains one or more electrochemical cells. Located at one or both lateral ends of each cell can are a cell vent and a pair of electrical terminals. Electrically connected to the battery cell terminals is an electrical busbar that is located inside the assembly housing, either between the cell stacks or laterally outboard of the cell stacks. Fluidly connected to the battery cell vents is a gas manifold that is located inside the assembly housing, either between the cell stacks or laterally outboard of the cell stacks.

Abstract: A method for manufacturing an electrode for a battery cells includes supplying an active material layer, a current collector, and a dummy current collector between a first roller and a second roller; using one of the first roller and the second roller, biasing the current collector into the active material layer below an outer surface of the active material layer using the dummy current collector; and removing the dummy current collector from the active material layer.

Abstract: A method for manufacturing a battery cell includes coating a three dimensional current collector (3DCC) with a lithiophilic metal oxide layer; and one of laminating the 3DCC with the lithiophilic metal oxide layer between a first lithium metal layer and a second lithium metal layer to create an anode electrode; and coating the 3DCC with the lithiophilic metal oxide layer with molten lithium to create an anode electrode.

Abstract: A method for manufacturing an anode electrode includes providing a first substrate, a second substrate, and an anode current collector. The method includes forming a first lithium metal layer on the first substrate and a second lithium metal layer on the second substrate. The method includes pressing the first lithium metal layer and the second lithium metal layer into the anode current collector to form an anode electrode.

Abstract: Aspects of the disclosure include a roll press design for manufacturing tailored porosity electrodes. An exemplary roll press includes a top roller and a bottom roller separated from the top roller by a gap. At least one of the top roller and the bottom roller includes a raised region and an indented region. The raised region includes a first radius and the indented region includes a second radius less than the first radius. The gap includes a distance selected to accommodate a current collector. The current collector includes a bare portion and a coated portion having thereon an electrode material of a first thickness. A difference between the first radius and the second radius is selected, based on the first thickness, to evenly distribute stress across the bare portion and the coated portion of the current collector during a calendering process for forming a tailored porosity electrode.