Abstract: A prismatic battery cell includes a cell can having a plurality of walls including a base wall, a first side wall, a second side wall, and a rear wall that collectively form an electrode stack receiving zone, a cap is mounted to the cell can, the cap forming a top wall and includes a terminal. A plurality of electrodes is arranged in the electrode stack receiving zone. The plurality of electrodes include a plurality of terminal foils. An interface system includes a connector assembly joining the plurality of terminal foils with the terminal. The connector assembly includes a first connector member and a second connector member. The plurality of terminal foils is arranged between and joined to the first connector member and the second connector member.

Abstract: A system including a busbar having a top surface and a bottom surface opposite the top surface, a terminal including a top surface and a bottom surface opposite the top surface, two or more welds applied to one of the top surface of the terminal or the bottom surface of the busbar, the two or more welds extending to a height between 0.1 mm and 0.2 mm and being configured to maintain a gap of between 0.1 mm and 0.2 mm in the subsequent welding area between the bottom surface of the busbar and the top surface of the terminal when the bottom surface of the busbar is mated with the top surface of the terminal, and one or more welds applied to the busbar and the terminal to secure the busbar to the terminal.

Abstract: A battery cell, a method of welding electrode foils in a battery, and a method of forming a battery cell. The battery includes a foil stack. The foil stack includes a plurality of foil tabs each extending from a current collector and at least one internal terminal lead. The battery further includes a weld joint formed between the plurality of foil tabs and the at least one terminal lead in the foil stack. A portion of the weld joint includes a weld nugget extending across the plurality of foils into the internal terminal lead, and the remainder of the weld joint includes a diffusion bonding zone extending around at least a portion of the weld nugget.

Abstract: A method for manufacturing a multi-layered and multi-functional thermoplastic composite structure includes supplying a plurality of reinforcing layers including continuous reinforcing fibers and thermoplastic resin to an intermittent press; and supplying at least one functional layer to the intermittent press adjacent to the plurality of reinforcing layers. The at least one functional layer is selected from a group consisting of an electromagnetic shielding layer and a thermal runaway protection layer. The method includes heating and pressing the plurality of reinforcing layers and the at least one functional layer to form a composite laminate.

Abstract: A rechargeable energy storage system for a vehicle including a bottom shear plate and a side enclosure having a bottom end connected to the bottom shear plate. A top shear plate is connected to a top end of the side enclosure and a plurality of battery cells are suspended from a bottom of the top shear plate by corresponding mating features that secure the plurality of cells to the top shear plate.

Abstract: A battery includes a prismatic cell can formed from steel. The prismatic cell can includes a first end, a second end spaced from the first end, a top surface, a bottom surface, a first side surface, and a second side surface that define a hollow can cavity. An anode current collector includes an anode foil tab. A cathode current collector includes a cathode foil tab. An anode terminal lead is secured to the anode foil tab. A cathode terminal lead is secured to the cathode foil tab. The anode current collector and the cathode current collector form an electrode stack arranged in the hollow can cavity with the anode terminal lead being connected to the bottom surface of the prismatic cell can forming a direct thermal pathway through the electrode stack to the bottom surface.

Abstract: A leak detection system includes an emitter, detector, and electronic control unit (ECU). The emitter directs electromagnetic energy having a predetermined wavelength range, e.g., infrared energy, toward a surface of a product. The product defines an enclosure chamber containing a trace gas. The detector is positioned between the emitter and the product at an offset distance from the surface. The detector detects reflected energy. The ECU receives a signal from the detector that is indicative of a spectrum of the reflected energy and identifies a detected leak in the product. This includes comparing the spectrum of the reflected energy to a predetermined spectrum of the trace gas. The trace gas has a wavelength within the predetermined wavelength range of the emitter. The ECU generates an output signal in response to the leak, with the output signal identifying a presence and location of the leak.

Abstract: A system configured to test battery cells. The system includes: a movable platform; a plurality of test stations movable by the movable platform, each one of the plurality of test stations configured to cooperate with a pallet on which the battery cells are seated, each one of the plurality of test stations including probes that are movable into cooperation with the battery cells and configured to inject gas into each one of the battery cells; and a camera adjacent to the movable platform and configured to detect leakage of the gas out from within any of the battery cells.

Abstract: A system configured to detect leakage of an electrolyte from a battery cell. The system includes: a probe configured to contact the battery cell and create an air-tight connection between the probe and the battery cell over a fill port of the battery cell that has been closed with a seal; a pump in fluid communication with the probe, the pump configured to draw a vacuum through the probe; a housing defining a chamber including a window, the probe extends from the housing, the pump is connected to the housing to draw the vacuum through the probe into the chamber; and a sensor configured to detect presence of the electrolyte within the chamber pulled from the battery cell through the seal of the fill port by the vacuum generated by the pump, presence of the electrolyte within the chamber is indicative of the seal of the fill port of the battery cell being compromised.

Abstract: A system configured to assess structural integrity of a battery pack component. The system includes: a tub configured to receive the battery pack component therein; a cover configured to sit on the tub and the battery pack component within the tub, and form a seal against both the tub and the battery pack component, thereby defining a reservoir between the tub, the cover, and the battery pack component; a pump configured to pump a gas into the reservoir through an inlet at the tub; and a sensor configured to detect a leak of the gas through the battery pack component from the reservoir, the leak corresponding to an area of the battery pack component having structural irregularities.

Abstract: A method for manufacturing a prismatic battery assembly includes disposing a plurality of current collector tabs at least partially through a slot of a cap of an enclosure. The plurality of current collector tabs are electrically connected to respective current collectors of an electrode stack and extend from an end of the electrode stack. The enclosure accommodates the electrode stack. The cap has an interior side that extends along the end of the electrode stack and an exterior side opposite the interior side. The slot is formed through the cap between the exterior side and the interior side. With the plurality of current collector tabs disposed at least partially through the slot, the method includes electrically connecting the plurality of current collector tabs to a terminal plate disposed at the exterior side of the cap and hermetically sealing the enclosure.

Abstract: A leak testing system includes a first test station, a second test station, a conveyor, and a controller. The first test station includes a first infrared camera equipped with a first optical CO2 lens filter, a first backdrop including a first heated surface and a first mirror, a first vacuum source, and a first CO2 gas delivery system. The second test station includes a second infrared camera equipped with a second optical CO2 lens filter, a second backdrop including a second heated surface and a second mirror, a second vacuum source, and a second CO2 gas delivery system. The first infrared camera is disposed to monitor a first field of view that includes the first backdrop. The second infrared camera is disposed to monitor a second field of view that includes the second backdrop. The controller includes a cell test procedure that is captured in algorithmic code.

Abstract: A leak detection system for a battery enclosure for one of a rechargeable energy storage system, a battery cell, a battery module, and/or a battery pack includes a gas delivery system configured to selectively provide a trace gas to the battery enclosure. A first optical gas imaging sensor is configured to generate images of a surface of the battery enclosure after the gas delivery system charges the battery enclosure with trace gas. The images are used to selectively detect a gas cloud adjacent to the surface of the of the battery enclosure. The gas cloud is used to determine a location of a gas leak on the surface of the battery enclosure.

Abstract: Presented are smart testing systems for detecting leaks in electrochemical devices, methods for making/using such testing systems, and memory-stored instructions for automating operation of such systems. A method of detecting a leak in an electrochemical device includes positioning a temperature-controlled (TC) screen with an electrothermal device at a predefined distance from an infrared camera to define therebetween a test envelope. A testing system controller commands the electrothermal device to modify the TC screen's operating temperature to a predefined screen testing temperature. After positioning an electrochemical device in the test envelope, between the TC screen and infrared camera, the infrared camera captures infrared images of the electrochemical device within the test envelope, showing the device's housing located in front of the TC screen. The system controller then analyzes the captured infrared images of the electrochemical device to determine if a gas leak is present in the device housing.

Abstract: Aspects of the disclosure include a joining strategy for resistance spot welding joints and components manufactured using the same. An exemplary vehicle includes a welded component having two or more layers. The welded component includes a first metal layer having a first conductivity and a second metal layer having a second conductivity. The first metal layer and the second metal layer are joined at a faying interface of a resistance spot-weld joint. The resistance spot-weld joint includes a continuous intermetallic layer at the faying interface directly between the first metal layer and the second metal layer and a pair of laser welds positioned on opposite sides of the continuous intermetallic layer. The pair of laser welds penetrate through the second metal layer and terminate within the first metal layer. The pair of laser welds extend into the first metal layer beyond a topmost surface of the continuous intermetallic layer.

Abstract: A roller offset forming tool includes a first roller configured to rotate in a first direction against a metal sheet. The first roller includes a first bead having a first shape. The tool includes a second roller disposed opposite and configured to engage with the first roller. The second roller is configured to rotate in a second direction that is opposite to the first direction against the metal sheet to thereby deform the metal sheet and form an offset feature therein. The second roller includes a secondary bead having a second geometry. The first bead is configured to align and mate with the secondary bead thereby hold the metal sheet between the first and second rollers. The first shape and the second geometry are configured to mitigate a distortion of the metal sheet in an area apart from the offset feature and stiffen the metal sheet at the offset feature.

Abstract: A method for consolidating a foil tab stack is provided. The method includes combining foil tabs of an electrode stack in a battery cell to form a combined foil tab stack. Additionally, the method includes hot-pressing the combined foil tab stack using heated pressing dies to form a consolidated foil tab stack. Further, the method includes laser welding the consolidated foil tab stack to a terminal lead using a laser welder.

Abstract: A heating system includes a conveying system configured to transport a plurality of vehicle body-in-whites (BIWs) sequentially through an oven room to cure paint applied in a paint room. A preheating system includes one or more robot arms. A heat source is connected to the one or more robot arms. A controller is configured to control the one or more robot arms based on a position of one of the vehicle BIWs on the conveying system and to position the heat source near or in direct contact with one or more inner components of the one of the vehicle BIWs to heat the one or more inner components prior to the one of the vehicle BIWs entering the oven room.

Abstract: A system for inspecting and revising welds. The system includes: a weld inspection sensor configured to inspect weld parameters of the welds; an inspection controller configured to identify one or more of the welds as an imperfect weld based on the weld parameters; a system controller configured to designate the imperfect weld for revision based on the weld parameters of, and relative locations of, the welds that are proximate to the imperfect weld designated for revision; a welding robot controller configured to operate a welding robot to perform a revision weld at the imperfect weld; and a weld verification sensor configured identify a revision location of the revision weld. The system controller is configured to verify the revision weld based on the revision location identified by the weld verification sensor.

Abstract: A laser brazing and welding system is disclosed and includes: a laser; a first cutting tool including a first cutting tip; and a control module. The control module is configured to control the laser to laser braze or laser weld two parts; and control ultrasonic vibration of the first cutting tip to remove one or more layers from at least one of the two parts prior to or subsequent to the laser brazing or laser welding of the two parts.