Abstract: A system for disassembling a energy cell having a case includes a energy cell securement device arranged on a moveable table; and a cutting tool. The energy cell securement device is configured to fixedly secure the energy cell with a portion of the case exposed proximal to the cutting tool. The moveable table is configured to convey the energy cell securement device such that the cutting tool cleaves the portion of the case of the energy cell.

Abstract: A process for local traffic approximation through analysis of cloud data is provided. The process includes, within a computerized traffic flow estimation controller of a host vehicle, operating programming to monitor a planned navigational route of the host vehicle, identify along the planned navigational route a road section including cross-traffic, monitor cloud data related to a mobile cellular device, analyze the cloud data to identify traffic posing a hazardous condition to the host vehicle within the road section, and generate a vehicle alert to a driver of the host vehicle based upon the identified traffic.

Abstract: A battery cell is provided. The battery cell includes an external container and an electrode stack disposed within the external container. The electrode stack includes at least one pair of an anode and a cathode. The battery cell further includes an electrolyte disposed within the external container and an O2 scavenger material disposed within the external container. The O2 scavenger material is configured for absorbing oxygen gas generated within the electrode stack.

Abstract: A battery cell includes an electrode stack including a pair of an anode and a cathode and a separator. Operation of the battery cell causes gas or moisture to form. The battery cell further includes a stiff frame. The frame includes a hollow portion. The electrode stack is disposed within the hollow portion. The frame includes a portion of the frame that is porous or includes a gas diffusion membrane. The battery cell further includes an electrolyte disposed within the frame and in contact with the electrode stack and a functional material disposed within the battery cell and outside of the hollow portion. The functional material absorbs the gas/moisture. The portion of the frame that is porous or includes a gas diffusion membrane enables the gas/moisture to exit the hollow portion and come into contact with the functional material while maintaining the electrolyte within the frame.

Abstract: The present disclosure includes a rotor core assembly for an electric motor. The rotor core assembly includes a plurality of laminations secured together. A center bore is defined by the plurality of laminations. A longitudinal axis of the rotor core assembly extends along an axial center of the center bore. A carbon fiber sleeve surrounds the plurality of laminations. Magnet slots are defined by the plurality of laminations. The magnet slots extend parallel to the longitudinal axis. Magnets are seated in the magnet slots. Reinforcing bores are defined by, and extend across, the plurality of laminations. Reinforcing members are seated in the reinforcing bores.

Abstract: A method of forming a plurality of embossments in a sheet of metal includes: (i) placing the sheet onto a first surface of a die having a plurality of embossment cavities thereon, wherein the sheet has a bottom surface in contact with the first surface of the die and a top surface having an ablative coating formed thereon; and (ii) directing a laser beam at the ablative coating at one or more loci on the top surface of the sheet which correspond to the plurality of embossment cavities on the first surface of the die, so as to locally ablate the ablative coating at the one or more loci and turn the ablative coating at the one or more loci into plasma, thereby causing a plasma pressure shock wave at each of the one or more loci which presses the sheet into the embossment cavities to form the embossments.

Abstract: An energy-dissipating cover for covering a component sensitive to mechanical impulse includes a sheet of selected ferrous or aluminum alloy, the sheet having a top surface, a bottom surface, an outer perimeter, an overall area within the outer perimeter and a nominal thickness of no more than 2.5 mm. The sheet is configured for connection with one or more external structures at a plurality of connection points within the outer perimeter, wherein the overall area comprises a plurality of supported areas and at least one unsupported area. Embossments are formed within the at least one unsupported area and extend outward from the bottom surface. The embossments are shaped, sized and arranged so as to limit orthogonal deflection of the sheet from a mechanical impulse directed normal to the bottom surface of the sheet at the plurality of embossments.

Abstract: A containment system for a rechargeable energy storage device (RESS) is described includes an enclosure having a first compartment adjoining a second compartment. The first compartment is arranged to house a plurality of power electronics devices, and the second compartment is arranged to house a plurality of battery cells. The second compartment includes a tub that defines a bottom portion, and a floor plate. The tub includes opposed end walls and opposed sidewalls. A top plate is arranged overtop of the first compartment and the second compartment. A first one of the end walls and the top plate define a first slot between the first compartment and the second compartment. A first removable panel is arranged to enclose the first compartment. The plurality of battery cells connect to the plurality of power electronics devices via a high-voltage DC power bus that is arranged to pass through the first slot.

Abstract: An injection molded composite component includes a groove extending from a first surface of the composite component and a tubing material placed within the groove and formed integrally with the composite component such that the tubing material forms an integrated conduit on the first surface of the composite component.

Abstract: A reinforced composite assembly includes a first sheet made of carbon fiber and having a first perimeter, a second sheet made of a non-carbon fiber material and having a second perimeter, wherein the second sheet is disposed atop the first sheet within the first perimeter, and a metallic plate having a third perimeter, wherein the metallic plate is disposed atop the second sheet within the second perimeter. The metallic plate has a plurality of holes formed therein about a perimeter of the metallic plate and defining a plurality of respective bridge portions between each of the holes and an adjacent outer edge of the metallic plate, and/or a plurality of extensions extending outward from a main portion of the metallic plate. A first arrangement of thread stitching secures each of the bridge portions and extensions to the second sheet or to the first and second sheets.

Abstract: A method and fixture for welding a battery foil-tab assembly is disclosed. The fixture includes a first clamp member having a first clamping surface defining an opening extending into the first clamp member and a second clamp member having a protrusion surrounding a weld slot. The opening of the first clamp member is configured to receive a portion of the protrusion with the battery foil-tab assembly disposed therebetween. The second clamp member is moveable toward the first clamp member to align the weld slot of the second clamp member with the opening of the first clamp member, thereby causing the protrusion to cooperate with the opening of the first clamp to deflect a portion of the battery foil-tab assembly out of a plane parallel with the battery foil-tab assembly. A laser beam is directed at the out of plane portion to laser weld the battery foil-tab assembly.

Abstract: An injection molded composite component includes a groove extending from a first surface of the composite component and a tubing material placed within the groove and formed integrally with the composite component such that the tubing material forms an integrated conduit on the first surface of the composite component.

Abstract: A rotary electric machine for use with coolant includes a stator and rotor assembly. The rotor assembly includes a rotor, rotor shaft, and first and second end rings. The rotor has inner and outer diameter surfaces and an embedded set of rotor magnets proximate the outer diameter surface. The shaft is connected to the rotor and defines a main coolant passage along an axis of rotation. Radial shaft coolant passages are in fluid communication with the main coolant passage. The end rings are positioned at opposing distal ends of the rotor. The shaft coolant passages direct the coolant into the rotor and/or the end rings such that the coolant flows axially through rotor cavities of the rotor and cools the rotor magnets via forced convection.

Abstract: The present disclosure provides a composite lift gate for a vehicle. The composite lift gate includes a polymer matrix and a fiber assembly. The fiber assembly is embedded in the polymer matrix. The fiber assembly includes a fiber mat and a plurality of substantially-aligned continuous fibers. The plurality of substantially-aligned continuous fibers is directly connected to a portion of the fiber mat. In one aspect, the composite lift gate further includes an electronic component connected to the fiber assembly. In various aspects, the present disclosure provides a method of manufacturing a composite lift gate for a vehicle.

Abstract: A reinforced composite assembly includes a first sheet made of carbon fiber and having a first perimeter, a second sheet made of a non-carbon fiber material and having a second perimeter, wherein the second sheet is disposed atop the first sheet within the first perimeter, and a metallic plate having a third perimeter, wherein the metallic plate is disposed atop the second sheet within the second perimeter. The metallic plate has a plurality of holes formed therein about a perimeter of the metallic plate and defining a plurality of respective bridge portions between each of the holes and an adjacent outer edge of the metallic plate, and/or a plurality of extensions extending outward from a main portion of the metallic plate. A first arrangement of thread stitching secures each of the bridge portions and extensions to the second sheet or to the first and second sheets.

Abstract: A mirror assembly includes a mirror housing and a mirror. The mirror is supported by the mirror housing. The mirror has an outer reflective surface. The mirror is bendable between a flat shape and a fisheye shape. The mirror assembly further includes an actuator assembly coupled to the mirror. Upon actuation, the actuator assembly is configured to bend the mirror between the flat shape and the fisheye shape to adjust a field of view of the mirror.

Abstract: A method and fixture for welding a battery foil-tab assembly is disclosed. The fixture includes a first clamp member having a first clamping surface defining an opening extending into the first clamp member and a second clamp member having a protrusion surrounding a weld slot. The opening of the first clamp member is configured to receive a portion of the protrusion with the battery foil-tab assembly disposed therebetween. The second clamp member is moveable toward the first clamp member to align the weld slot of the second clamp member with the opening of the first clamp member, thereby causing the protrusion to cooperate with the opening of the first clamp to deflect a portion of the battery foil-tab assembly out of a plane parallel with the battery foil-tab assembly. A laser beam is directed at the out of plane portion to laser weld the battery foil-tab assembly.

Abstract: A package for a power semiconductor device includes a housing, a power semiconductor module disposed within the housing, first and second fluidic channels extending through the housing on opposite sides of the power semiconductor module, and first and second arrays of heat transfer elements respectively disposed within the first and second fluidic channels. The first and second arrays of heat transfer elements are respectively physically bonded to first and second major surfaces of the power semiconductor module. A method of manufacturing a package for a power semiconductor device includes (i) respectively bonding first and second arrays of heat transfer elements to first and second major surfaces of a power semiconductor module, (ii) encapsulating the heat transfer elements within a sacrificial material, (iii) forming a housing around the sacrificial material and the heat transfer elements, and (iv) removing the sacrificial material from the housing to form first and second fluidic channels.

Abstract: A roll-and-peel tool includes a frame, a roller, two traction rims, a peeling wheel, and a trailer arm. A roller shaft is supported by the frame, and the roller is rotatable relative to the frame on the shaft. The traction rims are axially-spaced from one another with a roller midportion between the traction rims and the traction rims extending outward of the roller midportion. The peeling wheel is rotatable about a wheel shaft and has two traction hubs axially-spaced from one another and protrusions extending proud at an exterior surface of the peeling wheel between the traction hubs. The trailer arm connects the wheel and roller shafts so that the traction hubs interface with the traction rims and a gap is defined between the roller and the peeling wheel with the protrusions extending into the gap. A method of installing a trim component may be carried out with the tool.

Abstract: An energy-dissipating cover for covering a component sensitive to mechanical impulse includes a sheet of selected ferrous or aluminum alloy, the sheet having a top surface, a bottom surface, an outer perimeter, an overall area within the outer perimeter and a nominal thickness of no more than 2.5 mm. The sheet is configured for connection with one or more external structures at a plurality of connection points within the outer perimeter, wherein the overall area comprises a plurality of supported areas and at least one unsupported area. Embossments are formed within the at least one unsupported area and extend outward from the bottom surface. The embossments are shaped, sized and arranged so as to limit orthogonal deflection of the sheet from a mechanical impulse directed normal to the bottom surface of the sheet at the plurality of embossments.