Abstract: A method for manufacturing a battery cell having electrode foils protruding from a cell pouch includes positioning the cell pouch in a fixture such that distal end sections of the foils extend outward from the fixture. The method includes clamping the distal end sections in a curvilinear guide clamp to cause the distal end sections to taper into an electrode foil stack, and then translating the clamp a predetermined distance toward the fixture to displace the distal end sections by the predetermined distance. The method also includes trimming the distal end sections using a trim tool, positioning a sonotrode and an anvil adjacent opposite surfaces of the stack, and ultrasonically welding the stack to a conductive lead tab using the sonotrode to thereby form a welded joint within the battery cell. The sonotrode may be multi-sided with different knurl patterns for performing different welding processes.

Abstract: A method for manufacturing a battery cell having electrode foils protruding from a cell pouch includes positioning the cell pouch in a fixture such that distal end sections of the foils extend outward from the fixture. The method includes clamping the distal end sections in a curvilinear guide clamp to cause the distal end sections to taper into an electrode foil stack, and then translating the clamp a predetermined distance toward the fixture to displace the distal end sections by the predetermined distance. The method also includes trimming the distal end sections using a trim tool, positioning a sonotrode and an anvil adjacent opposite surfaces of the stack, and ultrasonically welding the stack to a conductive lead tab using the sonotrode to thereby form a welded joint within the battery cell. The sonotrode may be multi-sided with different knurl patterns for performing different welding processes.

Abstract: A method and associated device for joining a battery cell tab to a plurality of foils associated with a plurality of electrodes of a battery cell are described. This includes arranging the plurality of foils in a stack, and joining, via a first joining device, the plurality of foils, wherein the first joining device defines a joining region. A portion of the battery cell tab is arranged on the plurality of foils, and joined, via a second joining device, to the plurality of foils. The second joining device generates a weld joint that is encompassed within the joining region defined by the first joining device. In doing so, weld quality and strength of internal welds in a battery cell may be improved by reducing the occurrence of porosities and cracks in the foil/tab weld joints.

Abstract: The concepts described herein provide a hybrid metal/polymer current collector for a battery cell electrode that includes a collector body joined to a tab portion and encased in an electrically conductive overlay, and an associated method of manufacture. The tab portion is fabricated from a homogeneous electrically conductive material, the collector body is fabricated from a polymer, and the collector body is joined to the tab portion at a junction.

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 method and associated device for joining a battery cell tab to a plurality of foils associated with a plurality of electrodes of a battery cell are described. This includes arranging the plurality of foils in a stack, and joining, via a first joining device, the plurality of foils, wherein the first joining device defines a joining region. A portion of the battery cell tab is arranged on the plurality of foils, and joined, via a second joining device, to the plurality of foils. The second joining device generates a weld joint that is encompassed within the joining region defined by the first joining device. In doing so, weld quality and strength of internal welds in a battery cell may be improved by reducing the occurrence of porosities and cracks in the foil/tab weld joints.

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 computer software product adapted for use in a weld inspection system is executed by a processor and is stored in an electronic storage medium of the weld inspection system adapted to facilitate the inspection of a weld of a work product. The computer software product includes a first module and a combination module. The first module is configured to transform first and second raw thermal images, associated with respective first and second heat pulses of at least a portion of the work product having the weld, into respective first and second binary images. The combination module is configured to transform the first and second binary images into a combined binary image for the reduction of noise.

Abstract: A method for laser welding a plurality of battery foils to a battery tab that does not include ultrasonic welding and includes clamping the plurality of battery foils and the battery tab together. Each of the plurality of battery foils has a thickness that is between 0.004 millimeters and 0.03 millimeters. The battery tab has a thickness that is between 0.1 millimeters and 0.5 millimeters. The method further includes laser welding the plurality of battery foils to the battery tab.

Abstract: A workpiece is described, and includes a substrate, a cable, and a cover piece. A portion of the cable is joined to the substrate employing a vibration welding tool, and the cover piece is interposed between the portion of the cable and the vibration welding tool during the joining.

Abstract: A weld inspection system is adapted to inspect a weld of a work product via thermographic technology. The weld inspection system includes a heat source assembly, a thermal imaging camera, and a controller. The heat source assembly is adapted to sequentially direct a plurality of heat pulses upon the work product from varying perspectives and within a pre-determined time period. Thea thermal imaging camera is configured to thermally image the weld over the pre-determined time period and collect thermal imaging data of heat dissipation from the work product. The thermal imaging data is associated with the weld and the plurality of heat pulses. The controller is configured to control the heat source assembly and the thermal imaging camera. The controller includes a processor configured to receive and transform the thermal imaging data into a binary image for evaluation of the weld.

Abstract: A weld inspection system is adapted to inspect a weld of a work product via thermographic technology. The weld inspection system includes a heat source assembly, a thermal imaging camera, and a controller. The heat source assembly is adapted to sequentially direct a plurality of heat pulses upon the work product from varying perspectives and within a pre-determined time period. Thea thermal imaging camera is configured to thermally image the weld over the pre-determined time period and collect thermal imaging data of heat dissipation from the work product. The thermal imaging data is associated with the weld and the plurality of heat pulses. The controller is configured to control the heat source assembly and the thermal imaging camera. The controller includes a processor configured to receive and transform the thermal imaging data into a binary image for evaluation of the weld.

Abstract: A computer software product adapted for use in a weld inspection system is executed by a processor and is stored in an electronic storage medium of the weld inspection system adapted to facilitate the inspection of a weld of a work product. The computer software product includes a first module and a combination module. The first module is configured to transform first and second raw thermal images, associated with respective first and second heat pulses of at least a portion of the work product having the weld, into respective first and second binary images. The combination module is configured to transform the first and second binary images into a combined binary image for the reduction of noise.

Abstract: An exemplary system for storage and deployment of a drone from a vehicle includes a platform having a platform surface including a magnetic latching system configured to releasably secure the drone to the platform surface, a storage member enclosing the platform, the storage member defining a storage volume configured to enclose the drone when the drone is secured to the platform, an actuator configured to move the platform relative to the storage member, the platform movable between an enclosed position and an unenclosed position, and at least one controller in communication with the actuator, the at least one controller being configured to, in response to satisfaction of a first operating condition, control the actuator to move the platform to the unenclosed position, and, in response to satisfaction of a second operating condition, control the actuator to move the platform to the enclosed position.

Abstract: A probe for detecting discontinuities includes: a body portion; a head portion; one or more inductor coils located in the head portion and configured to: receive power from a power source; when power is received, induce an eddy current in a joint where a first metal component is joined with a second metal component; based on the induced eddy current, output a signal indicative of an inductance of the one or more inductor coils; and a plurality of positioning devices configured to maintain the one or more inductor coils approximately a predetermined distance from the surface.

Abstract: A drone landing method and system are provided. The method includes illuminator configured to determining a position and a speed of a vehicle based on vehicle information received via wireless communication, synchronizing the speed of the drone to the speed of the vehicle and maneuvering a drone to a position above a landing point on the vehicle based on the vehicle information, and landing the drone at the landing point of the vehicle.

Abstract: A method and a test fixture for evaluating a battery cell are described, wherein the battery cell is composed of a cell body having a plurality of electrode foils that are joined to both a positive terminal and a negative terminal at weld junctions. The method includes retaining the cell body of the battery cell in a first clamping device and gripping one of the positive and negative terminals in a terminal gripper. A dynamic stress end effector coupled to the terminal gripper is employed to apply a vibrational excitation load to the one of the positive and negative terminals. Impedance between the positive terminal and the negative terminal is monitored via a controller, and integrity of the weld junction of the one of the positive and negative terminals is evaluated based upon the impedance.

Abstract: A laser welder and associated method for joining battery cell foils to a battery tab is described. The joining method includes arranging the plurality of battery cell foils in a stack, wherein the first edges of the battery cell foils are disposed in parallel. The battery cell foils arranged in the stack are positioned such that the first edges of the battery cell foils underlap with the battery tab. A compressive load may be applied to the plurality of battery cell foils and the battery tab. The laser welder executes welding operation to form a weld joint that mechanically and electrically joins the battery cell foils and the battery tab. The welding operation includes the laser welder applying a laser beam to the second surface of the battery tab. The welding operation is executed near first edges of the battery cell foils.

Abstract: A lap belt pretensioner for a lap belt configured to secure an occupant of a vehicle seat includes a pyrotechnic device. The pyrotechnic device is configured to generate a force directed to tension the lap belt around the occupant and emit an exhaust gas including particulates at high pressure and high temperature as a byproduct of the generated force. The lap belt pretensioner also includes a housing configured to retain the pyrotechnic device and defining an exhaust passage configured to expel the exhaust gas from the lap belt pretensioner. The lap belt pretensioner additionally includes a shield arranged over the exhaust passage and configured to collect and/or deflect the emitted particulates and dissipate heat energy thereof. A vehicle having the vehicle seat mounted to the vehicle structure and employing the seatbelt system is also provided.

Abstract: A workpiece is described, and includes a substrate, a cable, and a cover piece. A portion of the cable is joined to the substrate employing a vibration welding tool, and the cover piece is interposed between the portion of the cable and the vibration welding tool during the joining.