Abstract: Provided are methods and systems for battery pack thermal management, such as heating and cooling of individual batteries arranged into battery packs. The methods and systems use thermal control modules, specifically configured to thermally couple to the side wall and the bottom end of each battery in a battery pack. In some examples, a thermal control module comprises a thermal plate and one or two battery engagement components, connected and thermally coupled to the thermal plate. Each battery engagement component comprises a plurality of battery receiving openings. When the batteries are installed into these openings, the side wall and the bottom end of each battery are thermally coupled to the thermal control module. Thermal fluid is circulated through at least the thermal plate to provide cooling or heating to the batteries without any direct contact between the thermal fluid and the batteries.

Abstract: A manufacturing process flow and accompanying methods for assembling a battery module are designed to increase efficiency, reduce a footprint of the manufacturing process, reduce manufacturing time, allow for increased flexibility, and reduce costs. The process flow takes advantage of robotic functionality to combine multiple manufacturing and quality assurance operations.

Abstract: An apparatus for holding a circuit against a battery module includes a set of first fixtures for holding a set of first conductive tabs of the circuit against a corresponding set of positive terminals of the battery module, a set of second fixtures for holding a set of second conductive tabs of the circuit against a corresponding set of negative terminals of the battery module, and a rigid plate having a set of first structures therein for receiving the set of first fixtures and having a set of second structures therein for receiving the set of second fixtures.

Abstract: An apparatus for holding a circuit against a battery module includes a set of first fixtures for holding a set of first tabs of the circuit against a corresponding set of positive terminals of the battery module, a set of second fixtures for holding a set of second tabs of the circuit against a corresponding set of negative terminals of the battery module, and a rigid plate having a set of openings therein for receiving the set of first fixtures and the set of second fixtures, the rigid plate configured for mounting to a structure holding the battery module.

Abstract: A manufacturing process flow and accompanying methods for assembling a battery module are designed to increase efficiency, reduce a footprint of the manufacturing process, reduce manufacturing time, allow for increased flexibility, and reduce costs. The process flow takes advantage of robotic functionality to combine multiple manufacturing and quality assurance operations.

Abstract: A manufacturing process flow and accompanying methods for assembling a battery module are designed to increase efficiency, reduce a footprint of the manufacturing process, reduce manufacturing time, allow for increased flexibility, and reduce costs. The process flow takes advantage of robotic functionality to combine multiple manufacturing and quality assurance operations.

Abstract: Provided are methods and systems for battery pack thermal management, such as heating and cooling of individual batteries arranged into battery packs. The methods and systems use thermal control modules, specifically configured to thermally couple to the side wall and the bottom end of each battery in a battery pack. In some examples, a thermal control module comprises a thermal plate and one or two battery engagement components, connected and thermally coupled to the thermal plate. Each battery engagement component comprises a plurality of battery receiving openings. When the batteries are installed into these openings, the side wall and the bottom end of each battery are thermally coupled to the thermal control module. Thermal fluid is circulated through at least the thermal plate to provide cooling or heating to the batteries without any direct contact between the thermal fluid and the batteries.

Abstract: Provided are methods and systems for battery pack thermal management, such as heating and cooling of individual batteries arranged into battery packs. The methods and systems use thermal control modules, specifically configured to thermally couple to the side wall and the bottom end of each battery in a battery pack. In some examples, a thermal control module comprises a thermal plate and one or two battery engagement components, connected and thermally coupled to the thermal plate. Each battery engagement component comprises a plurality of battery receiving openings.

Abstract: Provided are methods and systems for battery pack thermal management, such as heating and cooling of individual batteries arranged into battery packs. The methods and systems use thermal control modules, specifically configured to thermally couple to the side wall and the bottom end of each battery in a battery pack. In some examples, a thermal control module comprises a thermal plate and one or two battery engagement components, connected and thermally coupled to the thermal plate. Each battery engagement component comprises a plurality of battery receiving openings.

Abstract: An apparatus for holding a circuit against a battery module includes a set of first fixtures for holding a set of first conductive tabs of the circuit against a corresponding set of positive terminals of the battery module, a set of second fixtures for holding a set of second conductive tabs of the circuit against a corresponding set of negative terminals of the battery module, and a rigid plate having a set of first structures therein for receiving the set of first fixtures and having a set of second structures therein for receiving the set of second fixtures.

Abstract: A welding method includes providing a first workpiece and a second workpiece, positioning the first workpiece to contact the second workpiece, coating a portion of a selected one of the first and second workpieces with an absorbing layer; and welding the first workpiece and the second workpiece by heating the selected one of the first and second workpieces through the absorbing layer.

Abstract: An apparatus for holding a circuit against a battery module includes a set of first fixtures for holding a set of first tabs of the circuit against a corresponding set of positive terminals of the battery module, a set of second fixtures for holding a set of second tabs of the circuit against a corresponding set of negative terminals of the battery module, and a rigid plate having a set of openings therein for receiving the set of first fixtures and the set of second fixtures, the rigid plate configured for mounting to a structure holding the battery module.

Abstract: A manufacturing process flow and accompanying methods for assembling a battery module are designed to increase efficiency, reduce a footprint of the manufacturing process, reduce manufacturing time, allow for increased flexibility, and reduce costs. The process flow takes advantage of robotic functionality to combine multiple manufacturing and quality assurance operations.

Abstract: A bending tool is disclosed. The bending tool may include a male fixture that may have a projection with an outer surface and a female fixture that may be configured to receive the projection. The female fixture may have a first height in a direction that is substantially parallel to the projection. The bending tool may also include a positioning device, which may be disposed between the male fixture and the female fixture. The male fixture may be configured to move between a starting position and an ending position in which the outer surface of the projection is received by the female fixture at a pre-determined distance below the first height.