Abstract: Systems and methods to improve weld quality are described. For example, certain systems and methods described use weld quality monitoring as feedback to an ultrasonic welding process to improve weld quality. Still other systems and methods provide improvement to double sided and single sided ultrasonic welding through the use of selected multiple pulses.

Abstract: A multi-user electric vehicle charging station is described, and includes a movable charging apparatus that is disposed to service a plurality of parking spaces and a controller that operatively connects to the movable charging apparatus. A human/machine interface device communicates with the controller and includes an interface device including user-selectable states including a user identification, identification of a specific one of the parking spaces and an expected departure time associated with a vehicle parked in the specific one of the parking spaces.

Abstract: A method of resistance spot welding workpiece stack-ups of different combinations of steel workpieces and aluminum workpieces includes several steps. In one step, a workpiece stack-up is brought between a first weld gun arm and a second weld gun arm. The first weld gun arm includes a first welding electrode, and the second weld gun arm includes a carrier that supports a second welding electrode and a third welding electrode. Another step involves rotating the carrier and passing electrical current through the workpiece stack-up using the first welding electrode in conjunction with either the second welding electrode or the third welding electrode depending on which electrode has been rotated into facing alignment with the first welding electrode.

Abstract: The present technology discloses methods for joining a first workpiece and a second workpiece through an interlocking weld, and products formed thereby. The first workpiece has a first surface and a second surface opposite the first surface, and the second workpiece has a first surface, a groove formed in the first surface, and a second surface opposite the first surface. The system is formed by applying energy to the system, at least partially melting material of the first workpiece, and causing the material to flow into the groove, and allowing or causing the material to cool, forming an interlocked-weld joint connecting the workpieces.

Abstract: In one embodiment, a reconfigurable vehicle interior assembly is provided. The assembly includes a trim member including a plurality of first elastically deformable mating members and a vehicle interior carrier component including a plurality of second elastically deformable mating members. Each of the first elastically deformable mating members matingly engages with at least one of the second elastically deformable mating members in order to couple the trim member to the vehicle interior carrier component. The first and second elastically deformable mating members collectively form a plurality of elastic averaging couplings.

Abstract: An interconnect member for use in a vibration welded battery module having a battery tab includes a portion weldable to the battery tab, and an inlay. The inlay is positioned with respect to the portion. The inlay may be the same material as the portion, with an insulating or heat-deterring outer ring, or may be the same material as the battery tab with or without the outer ring. Voids or openings may be provided in the interconnect member to reduce the thermal mass of the interconnect member. The voids may be defined by laminated or clad layers of the portion, and may be filled with an insulating material. A battery module is also disclosed having the battery tabs and the interconnect member noted above.

Abstract: A welding assembly for forming a weld along a welding interface of a work piece(s) using vibrations includes a welding tool and a thermal barrier. The thermal barrier is at least a chemical and/or mechanical insulating layer positioned adjacent to the welding tool, which minimizes the rate of dissipation of heat generated by the vibrations at or along the welding interface. The welding assembly may also include a wear-resistant layer adjacent to the thermal barrier, which protects the thermal barrier from damage or wear. The welding tool is a portion an anvil assembly and/or a sonotrode assembly. A method of insulating a welding tool includes applying or connecting a thermal barrier to a surface of the welding tool, and minimizing the rate of dissipation of heat generated by the vibrations at or along the welding interface using the thermal barrier, which includes an insulating layer.

Abstract: A method for heating a work piece or a welding interface using a vibration welding system includes positioning the work piece adjacent to a welding tool to define the welding interface and then heating the work piece or the welding interface to within a calibrated threshold temperature using a thermal device, e.g., a heat rod, laser device, or blower. A high-frequency vibration may be applied to form a weld. The work piece may include an adjacent interconnecting member and battery tab. The thermal device may be embedded within the welding tool and controlled via a temperature controller. A vibration welding system includes a welding tool, a thermal device, and a controller. The controller controls the thermal device to thereby control the welding temperature at or along the welding interface. The thermal device may be embedded within the welding tool, which may be configured as an anvil body in one embodiment.

Abstract: An interconnect member for use in a vibration welded battery module having a battery tab includes a portion weldable to the battery tab, and an inlay. The inlay is positioned with respect to the portion. The inlay may be the same material as the portion, with an insulating or heat-deterring outer ring, or may be the same material as the battery tab with or without the outer ring. Voids or openings may be provided in the interconnect member to reduce the thermal mass of the interconnect member. The voids may be defined by laminated or clad layers of the portion, and may be filled with an insulating material. A battery module is also disclosed having the battery tabs and the interconnect member noted above.