Abstract: In an embodiment, an expansion component (e.g., expanding foam element, inflatable pad, a pneumatic or hydraulic mechanism, etc.) is arranged inside of a battery module compartment (e.g., on a bottom interior surface of the battery module compartment). A battery module is inserted into the battery module component and is fixated, or secured, within the battery module compartment at least in part based upon the expanding component which starts to expand or continues to expand after the insertion. In a further embodiment, the battery module may be removed from the battery module compartment after a contraction function (e.g., collapse of the foam element, deflation of the inflatable pad, etc.) of the expansion component is initiated.

Abstract: A method of additive manufacture suitable for large and high resolution structures is disclosed. The method may include sequentially advancing each portion of a continuous part in the longitudinal direction from a first zone to a second zone. In the first zone, selected granules of a granular material may be amalgamated. In the second zone, unamalgamated granules of the granular material may be removed. The method may further include advancing a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone.

Abstract: An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved optical systems supporting beam combining, beam steering, and both patterned and unpatterned beam recycling and re-use are described.

Abstract: An embodiment is directed to a multi-layer contact plate configured to establish electrical bonds to battery cells in a battery module. The multi-layer contact plate includes two or more primary conductive layers (e.g., Al, Cu, etc.), and a cell terminal connection layer (e.g., steel, Al, Cu, etc.) that is joined with, and sandwiched by, the two or more primary conductive layers. A portion of the cell terminal connection layer is configured to form a set of bonding connectors (e.g., bonding ribbons) to provide a direct electrical bond between the multi-layer contact plate and terminals (e.g., positive terminals, negative terminals, or a combination thereof) of at least one group of battery cells (e.g., a single group of battery cells, two groups of battery cells that are connected in series, etc.).

Abstract: A method of additive manufacture is disclosed. The method may include creating, by a 3D printer contained within an enclosure, a part having a weight greater than or equal to 2,000 kilograms. A gas management system may maintain gaseous oxygen within the enclosure atmospheric level. In some embodiments, a wheeled vehicle may transport the part from inside the enclosure, through an airlock, as the airlock operates to buffer between a gaseous environment within the enclosure and a gaseous environment outside the enclosure, and to a location exterior to both the enclosure and the airlock.

Abstract: A method of additive manufacture is disclosed. The method may include restricting, by an enclosure, an exchange of gaseous matter between an interior of the enclosure and an exterior of the enclosure. The method may further include running multiple machines within the enclosure. Each of the machines may execute its own process of additive manufacture. While the machines are running, a gas management system may maintain gaseous oxygen within the enclosure at or below a limiting oxygen concentration for the interior.

Abstract: An embodiment is directed to a battery module, including a plurality of battery cell groups that are connected in series with each other, each of the plurality of battery cell groups including a plurality of battery cells that are connected to each other in parallel, a first terminal component at a first terminal of the battery module, the first terminal corresponding to either a positive terminal of the battery module or a negative terminal of the battery module, and a first heat pipe positioned in proximity to the first terminal component and configured to transfer heat away from the first terminal component.

Abstract: In an embodiment, a battery module is provided with a cooling tube configured to carry liquid coolant for cooling a set of battery cells inside the battery module. A portion of the cooling tube being arranged beneath the set of battery cells and includes an integrated turbulator component configured to transition a flow of the liquid coolant from a laminar flow to a turbulent flow. In an example, the integrated turbulator component may be formed by integrating a turbulent component into a tube (e.g., a straight tube), and then bending the tube to produce the cooling tube portion.

Abstract: An embodiment is directed to a method of fabricating a multi-layer contact plate, comprising providing a layer stack with first, second and third conductive layers, inserting brazing material into holes first and/or second conductive layers of a layer stack, and brazing the layer stack after the inserting. Another embodiment is directed to a multi-layer contact plate, comprising a layer stack with first, second and third conductive layers, with at least one inter-layer connection including a brazed area where the second conductive layer is brazed to each of the first and third conductive layers, and where the first and third conductive layers are directly brazed to each other through a hole in the second conductive layer.

Abstract: An embodiment is directed to a contact plate configured to establish electrical bonds between battery cells in a battery module, including at least one primary conductive layer, and a set of bonding connectors that are configured to provide direct electrical bonds between the contact plate and terminals of a group of battery cells, the set of bonding connectors being configured to connect the group of battery cells in parallel with each other, wherein at least one bonding connector in the set of bonding connectors is configured with a higher fuse rating than each other bonding connector in the set of bonding connectors so as to contain arcs among the set of bonding connectors to the at least one bonding connector.

Abstract: An embodiment is directed to a contact plate configured to establish electrical bonds between battery cells in a battery module, including at least one primary conductive layer, and a set of bonding connectors that are configured to provide direct electrical bonds between the contact plate and terminals of a group of battery cells, the set of bonding connectors being configured to connect the group of battery cells in parallel with each other, wherein at least one bonding connector in the set of bonding connectors is configured with a higher fuse rating than each other bonding connector in the set of bonding connectors so as to contain arcs among the set of bonding connectors to the at least one bonding connector.

Abstract: A connecting element for at least two energy storage cells, having a metal sheet for the electrical connection of the energy storage cells. The metal sheet has at least two perforations for the uptake in each perforation of at least a part of an energy storage cell. Two lugs provided on the metal sheet project into the perforations.

Abstract: In an embodiment, a multi-cell hold-down mechanism is clamped over multiple contact tabs aligned with respective cell terminals (e.g., positive and/or negative cell terminal(s). While clamped, the contact tabs are securely welded to respective cell terminals through respective gaps in the multi-cell hold-down mechanism. In another embodiment, a multi-cell hold-down mechanism is clamped over an electrically conductive part that is coupled to multiple cell rims which are configured as negative cell terminals. A respective negative contact tab is welded to the electrically conductive part through a gap in the multi-cell hold-down mechanism. In another embodiment, three (or more) battery cell terminals (e.g., positive or negative terminals) are coupled to an electrically conductive bar that is welded to a contact tab of a busbar.

Abstract: In an aspect, a battery module is assembly by mounting first and second jig towers (e.g., monolithic or modular/stackable jig towers) on a surface. Battery cell(s) are arranged between the jig towers and fixed in position based in part on battery cell fixation elements arranged in the respective jig towers. At least one magnetic-based supplemental fixation element is used to apply magnetic force (e.g., attractive and/or repulsive magnetic force) so as to direct the battery cell(s) towards the first jig tower and away from the second jig tower (e.g., so that battery cells in respective rows will be flush with each other).

Abstract: An aspect is directed to a contact plate arrangement for a battery module. The contact plate arrangement comprises a first contact plate connected to first terminals of a first parallel group of battery cells (P-Group) and to second terminals of a second P-Group, a second contact plate that is partially stacked over the first contact plate, the second contact plate connected to first terminals of the second P-Group and to second terminals of a third P-Group, and a third contact plate that is partially stacked over the second contact plate, the third contact plate connected to first terminals of the third P-Group.

Abstract: An embodiment is directed to a battery module, including a plurality of battery cell groups that are connected in series with each other, each of the plurality of battery cell groups including a plurality of battery cells that are connected to each other in parallel, a first terminal component at a first terminal of the battery module, the first terminal corresponding to either a positive terminal of the battery module or a negative terminal of the battery module, and a first heat pipe positioned in proximity to the first terminal component and configured to transfer heat away from the first terminal component.

Abstract: An embodiment of the disclosure is directed to a multi-layer contact plate configured to establish electrical bonds to battery cells in a battery module, comprising a first plate section configured with a first set of raised dimples on an inner side of the first plate section, a second plate section configured with a second set of raised dimples on an inner side of the second plate section, a cell terminal connection layer sandwiched between the first and second plate sections, wherein a portion of the cell terminal connection layer is configured to form a set of bonding connectors to provide a direct electrical bond between the multi-layer contact plate and terminals of at least one group of battery cells, and a set of inter-layer connection points arranged between at least the first and second plate sections, each of the set of inter-layer connection points being arranged where raised dimples on the first and second plate sections are aligned with each other.

Abstract: An energy storage arrangement includes an energy storage receptacle which has multiple cup-shaped receiving compartments and energy storages respective positive and a negative electrode and being received in the receiving compartments, wherein one of the electrodes of each of the energy storages is in electrically conductive contact with the receiving compartment that receives the respective energy storage and the electrodes of all energy storages that are in contact with the energy storage receptacle are electrically conductively connected via the energy storage receptacle.

Abstract: An energy storage arrangement, includes multiple energy storages, each energy storage having a housing and a terminal connection, wherein the terminal connection lies on an electrostatic potential of a first terminal of the energy storage and is arranged on an end side of the energy storage, wherein the housing lies on an electrostatic potential of a second terminal of the energy storage. The energy storage arrangement further has a first busbar electrically conductively fastened on the terminal connection of each of the energy storages, and a second busbar electrically conductively fastened on the housing on the end side of the energy arrangement on which the first busbar is arranged.

Abstract: A method and an apparatus for collecting powder samples in real-time in powder bed fusion additive manufacturing may involves an ingester system for in-process collection and characterizations of powder samples. The collection may be performed periodically and uses the results of characterizations for adjustments in the powder bed fusion process. The ingester system of the present disclosure is capable of packaging powder samples collected in real-time into storage containers serving a multitude purposes of audit, process adjustments or actions.