Abstract: In one embodiment, an electrochemical system includes an interconnector busbar including a substrate and a coating contacting the substrate, the coating including a layer of electroplated elemental nickel.

Abstract: In one embodiment, a method of evaluating a battery module includes: applying a tension load to a test coupon, the test coupon including a segment of a battery terminal connected to a segment of an interconnector busbar; and measuring electrical resistance across the segments of the test coupon. In certain instances, the method further includes applying a different, second tension load to the segments of the test coupon and repeating the measuring of electrical resistance. In certain other instances, the method further includes forming a plot between various values of electrical resistance as a function of various tension loads.

Abstract: In one embodiment, a method of evaluating electric joints includes: partially separating a terminal portion from a busbar portion of a joint formed between a battery cell terminal and an interconnector busbar; and measuring electric resistance between the terminal portion and the busbar portion. In another embodiment, the step of measuring includes connecting the terminal portion of the joint to a first clip of a first polarity and connecting the busbar portion of the joint to a second clip of an opposing polarity.

Abstract: A method for in-line cleaning of ultrasonic welding tools is described. The method includes applying cleaning solution onto a work surface of a welding tool to be cleaned using an application device. Then the method involves removing residue dissolved in the cleaning solution from the work surface using a cleaning device. Next, the work surface is neutralized and rinsed using purified water and polished with a cleaning cloth. Finally, the work surface is rinsed using cleaning alcohol and blow-dried with compressed air.

Abstract: In one embodiment, an electrochemical system includes an interconnector busbar including a substrate and a coating contacting the substrate, the coating including a layer of electroplated elemental nickel.

Abstract: Ultrasonic welding tools for joining two or more components include a horn and an anvil. The horn work surface(s) has a plurality of protrusions, each having a base, a lower portion projecting from the base, and an upper domed portion projecting from the lower portion, substantially resembling a domed cone. The anvil work surface(s) has a plurality of protrusions, each having a basal portion and an upper tapering portion projecting from the base, substantially resembling a pyramid. The span of each pyramid base is no greater than the span of each domed cone base. The geometric center of each domed cone base on each horn work surface aligns with the geometric center of the valley surrounded by four adjacent pyramids on the matching anvil work surface.

Abstract: In one embodiment, a battery cell terminal includes a terminal substrate; an interconnector busbar including a busbar substrate; and a coating disposed between and contacting at least one of the terminal and busbar substrates, the coating including a metal and having a melting temperature smaller than a melting temperature of the terminal or busbar substrate. In another embodiment, the coating includes a first coating of a metal M1 and second coating of a metal M2, the first coating contacting the terminal substrate, and the second coating contacting the busbar substrate.

Abstract: In one embodiment, an electrochemical system includes an interconnector busbar including a substrate and a coating contacting the substrate, the coating including a layer of electroplated elemental nickel.

Abstract: In one embodiment, a method of evaluating a battery module includes: applying a tension load to a test coupon, the test coupon including a segment of a battery terminal connected to a segment of an interconnector busbar; and measuring electrical resistance across the segments of the test coupon. In certain instances, the method further includes applying a different, second tension load to the segments of the test coupon and repeating the measuring of electrical resistance. In certain other instances, the method further includes forming a plot between various values of electrical resistance as a function of various tension loads.

Abstract: In one embodiment, a method of evaluating electric joints includes: partially separating a terminal portion from a busbar portion of a joint formed between a battery cell terminal and an interconnector busbar; and measuring electric resistance between the terminal portion and the busbar portion. In another embodiment, the step of measuring includes connecting the terminal portion of the joint to a first clip of a first polarity and connecting the busbar portion of the joint to a second clip of an opposing polarity.

Abstract: A method for in-line cleaning of ultrasonic welding tools is described. The method includes applying cleaning solution onto a work surface of a welding tool to be cleaned using an application device. Then the method involves removing residue dissolved in the cleaning solution from the work surface using a cleaning device. Next, the work surface is neutralized and rinsed using purified water and polished with a cleaning cloth. Finally, the work surface is rinsed using cleaning alcohol and blow-dried with compressed air.