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 for manufacturing a tubular enclosure for a battery cell includes bending a steel sheet into a tubular body. The steel comprises iron; carbon in a range from 0.01 wt % to 0.1 wt %; niobium in a range from 0.01 to 0.2 wt %; and at least one of a first group and a second group. The first group comprises copper in a range from 0.01 to 2.0 wt %; nickel in a range from 1 to 6.0 wt %; aluminum in a range from 0.1 to 1.0 wt %; manganese in a range from 0.1 to 1.0 wt %; and molybdenum in a range from 0.1 to 2.0 wt %. The second group comprises titanium in a range from 0.1 to 1.5 wt %; and silicon in a range from 0.1 to 1.5 wt %. Edges of the tubular body are welded and the tubular body is age hardened.

Abstract: A method for manufacturing a tubular enclosure for a battery cell includes roll forming a sheet of steel into a tubular body. The steel comprises carbon in a range from 0.02 to 0.3 wt %, manganese in a range from 0.2 to 2.0 wt %, at least one of chromium and molybdenum in a range from 0.5 wt % to 3.0 wt %, silicon in a range from 0.2 wt % to 2.0 wt %, at least one of niobium, titanium, and vanadium in a range from 0.01 wt % to 0.2 wt %, and iron. The method includes welding sides of the tubular body to form a weld seam, heating the tubular body to a temperature in a range from 900° C. to 950° C., and quenching the tubular body.

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 battery system for a motor vehicle or another electrical system includes a battery cover, one or more battery cells, and a diverter assembly. The cells define a battery cavity in fluid communication with a corresponding vent opening. An air gap may be defined in an exhaust volume within the battery system. The diverter assembly includes a diverter body arranged relative to the vent openings. The diverter body is moveable or stationary. In response to a thermal propagation event occurring in the module or at least one of the battery cells, each diverter body diverts a high-temperature flow of ejecta from the cavity into an exhaust volume in a predetermined flow direction when the flow of ejecta passes through the vent opening. The diverter assembly may include a support member connected to the diverter body and connectable to the battery cell.

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 an anode electrode includes supplying an anode current collector; coating a first portion of the anode current collector with a precursor coating; not coating a second portion of the anode current collector with the precursor coating; treating the anode current collector with plasma to at least one of decrease lithium wettability of the first portion and to increase lithium wettability of the second portion; and coating the anode current collector with lithium metal to form an anode active material layer.

Abstract: A battery module includes a container, a plurality of battery cells within the container, and a cover attached to sides of the container and extending in a plane over the plurality of battery cells wherein the cover comprises an inner layer and an outer layer. Upon a thermal event in one of the cells the battery cover can deflect inward toward the cells.

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 of making a cold plate includes stacking three aluminum sheets on top of each other while each of the three aluminum sheets is generally flat. An edge of the three aluminum sheets are secured together. A top one of the aluminum sheets is welded to a middle one of the aluminum sheets at a plurality of first locations and a bottom one of the aluminum sheets is welded to the middle one of the aluminum sheets at a plurality of second locations different than the plurality of first locations. A pressurized medium is supplied between the top one of the aluminum sheets and the bottom one of the aluminum sheets to separate the top one of the aluminum sheets from the bottom one of the aluminum sheets and deform the middle one of the aluminum sheets.

Abstract: An enclosure body and a method for manufacturing an enclosure includes one of extruding and deep drawing an enclosure including a plurality of side walls defining a first cavity. The plurality of side walls are formed without stiffening portions. After extruding and deep drawing of the enclosure, forming a plurality of stiffening portions on the enclosure using an expandable punch, a hydraulic punch, and/or hydroforming.

Abstract: Methods for fabricating an anode, methods for fabricating a battery, and lithium batteries are disclosed. A method for fabricating an anode includes forming a melt comprising lithium and a surface tension reduction agent, wherein the surface tension reduction agent is selected from the group consisting of silver, tin, gallium, indium, zinc, and combinations thereof; and contacting an anode current collector with the melt, wherein a layer of the melt wets onto the anode current collector to form the anode as a lithium alloy.

Abstract: A battery cell includes a battery cell stack including A anode electrodes including an anode active material layer arranged adjacent to an anode current collector; C cathode electrodes including a cathode active material layer arranged adjacent to a cathode current collector; and S separators arranged between the A anode electrodes and the C cathode electrodes. The anode active material layer of the A anode electrodes includes a lithium metal layer and a lithium alloy layer comprising an alloy of lithium and a lithiophilic metal.

Abstract: A method for manufacturing an anode electrode for a battery cell includes providing a current collector; and forming a layer on the current collector to create a coated current collector. The layer includes one of a metal and a metal oxide that is not miscible in molten lithium. The method includes immersing the coated current collector in molten lithium to coat the coated current collector.

Abstract: A battery cell includes a battery cell stack including A anode electrodes, C cathode electrodes, and S separators, where A, C, and S are integers greater than one. A double-walled prismatic enclosure is configured to house the battery cell stack including a can body including an inner enclosure, an outer enclosure, and a gap between the inner enclosure and the outer enclosure. The battery cell stack is arranged in the inner enclosure. The outer enclosure of the can body defines a first opening and a second opening at opposite ends thereof. A first lid portion is attached to the first opening of the outer enclosure. A first bottom portion is attached to the second opening of the outer enclosure.

Abstract: A battery cell including a can body of an enclosure comprising a sheet of metal that is folded into an open cylindrical shape and welded. The can body includes a first opening and a second opening at opposite ends of the can body. The can body is configured to receive a battery cell stack. A lid portion of the enclosure is attached to the first opening of the can body. A bottom portion of the enclosure is attached to the second opening of the can body.

Abstract: A battery cell comprises a battery cell stack including A anode electrodes; C cathode electrodes; and S separators, where A, C, and S are integers greater than one. An enclosure configured to house the battery cell stack includes a can body defining a first opening and a second opening at opposite ends of the can body; a lid portion joined to the first opening of the can body by a first brazed filler material that is arranged between the lid portion and the can body and that has a first melting temperature; and a bottom portion joined to the second opening of the can body.

Abstract: A method for manufacturing a current collector for an electrode of a battery cell includes providing a wire mesh current collector including a plurality of first wires and a plurality of second wires that overlap to form a plurality of mesh joints. A diameter of the plurality of first wires and the plurality of second wires is in a range from 4 ?m to 100 ?m. The method includes coating the wire mesh current collector with a metal coating by immersing the wire mesh current collector in a bath including a metal salt.

Abstract: A method for manufacturing a current collector for an electrode of a battery cell includes providing a wire mesh current collector including wires that have a diameter and form mesh junctions; and rolling the wire mesh current collector using a first roller and a second roller, wherein the first roller and the second roller are spaced by a predetermined gap. The predetermined gap is less than 2 times the diameter of the wires of the wire mesh current collector.