Abstract: A method for bonding a metal electrode layer and a current collector includes supplying a first metal electrode layer, a current collector layer, and a second metal electrode layer for a battery cell between a first roller and a second roller; connecting a power supply to the first roller and the second roller; and supplying current through the first roller, the first metal electrode layer, the current collector layer, and the second metal electrode layer and the second roller to cause joule heating and bonding of the first metal electrode layer, the current collector layer, and the second metal electrode layer.

Abstract: A battery cell includes cathode electrodes including cathode electrode coatings arranged on cathode current collectors, and anode electrodes including anode electrode coatings arranged on anode current collectors. The cathode electrodes and the anode electrodes are arranged in a predetermined order in a stack. The cathode current collectors include first external tabs in a first asymmetric position and second external tabs in a second asymmetric position. The first external tabs and the second external tabs of the cathode electrodes are welded to a cathode lead tab. The anode current collectors include first external tabs in a first asymmetric position and second external tabs in a second asymmetric position. The first external tabs and the second external tabs of the anode electrodes are welded to an anode lead tab.

Abstract: Disclosed herein is a device for magnetic welding of battery boils comprising a coil holder; where the coil holder comprises one or more electrical coils that are operative to be activated by an electrical current; a foil holding fixture; wherein the foil holding fixture comprises a plurality of arms; wherein each pair of adjacent arms is operative to move towards one another to crimp a plurality of battery foils; and an anvil; wherein the anvil is operative to support a battery tab and the battery foils.

Abstract: An electrode calendering system for reducing post-calendering electrode wrinkling includes at least one roller configured to compress an electrode and a sleeve. The roller is defined by an outer surface configured to contact the electrode. The outer surface has a first edge portion at a first side of the roller and a second edge portion at a second side of the roller opposing the first side. The first edge portion and the second edge portion of the roller align with first and second outer edges of the electrode when the electrode contacts the roller. The sleeve is disposed about the outer surface of the roller along the first edge portion, the sleeve having a controllable thickness to adjust a pressure between the first outer edge of the electrode and the sleeve. Other example systems and methods for reducing post-calendering electrode wrinkling are also disclosed.

Abstract: A heating system includes a conveying system configured to transport a plurality of vehicle body-in-whites (BIWs) sequentially through an oven room to cure paint applied in a paint room. A preheating system includes one or more robot arms. A heat source is connected to the one or more robot arms. A controller is configured to control the one or more robot arms based on a position of one of the vehicle BIWs on the conveying system and to position the heat source near or in direct contact with one or more inner components of the one of the vehicle BIWs to heat the one or more inner components prior to the one of the vehicle BIWs entering the oven room.

Abstract: A defect detection system includes: sensors of different types configured to scan battery electrode material and generate output signals including respective image data; a feature extractor module receives the output signals and performs feature extraction to fuse the image data of the output signals to generate feature maps for respective portions of the battery electrode material; a coarse detector, based on the feature maps, determines whether there are defects in the portions of the battery electrode material, and generates binary information for each of the portions indicating whether the portions include one or more defects; and a fine detector, based on the binary information and at least one of the feature maps and image data, classifies the defects. A control module performs one or more operations based on the detected and classified defects.

Abstract: Aspects of the disclosure include an electrode calendering system that leverages electrode foil edge tensioning to reduce calendering wrinkling and a process for manufacturing electrodes using the same. An exemplary system includes a calendering module having a pair of calendering rollers separated by a gap. The gap includes a distance selected to accommodate a current collector. The current collector includes a bare portion and a coated portion having thereon an active electrode material of a first thickness. The system includes an un-winder module upstream of the calendering module, a collector module downstream of the calendering module, and one or more idle rollers. An idle roller of the one or more idle rollers includes a tensioning sleeve having a second thickness selected, based on the first thickness, to over-tension underlying portions of the current collector, the tensioning sleeve aligned to the bare portion of the current collector.

Abstract: A method for forming an electrode, the method including: applying an active layer on a transfer device configured to move the active layer onto a current collector, the active layer including at least one binder, at least one active material, and at least one solvent; heating the active layer to evaporate the at least one solvent and draw the at least one binder to an outer surface of the active layer; and after heating the active layer, applying the active layer to the current collector with the outer surface in contact with the current collector.

Abstract: A mixing device includes a source of pressurized gas and a mixing chamber. A gas blade nozzle is disposed within the mixing chamber and connected to the source of pressurized gas.

Abstract: Some embodiments disclosed herein are directed to battery cells with corrugated foil tabs. Some embodiments may include a battery cell comprising a cathode, an anode and a corrugated foil tab coupled to the cathode or the anode, wherein the corrugated foil tab has a length in a first plane, includes alternating peaks and troughs in a second plane along the length of the corrugated foil tab, and has a width in a third plane, and wherein the first plane, second plane, and third plane are orthogonal to each other. Other embodiments may be disclosed or claimed.

Abstract: A method for manufacturing an anode electrode includes providing a current collector layer on a rolling surface; arranging N strips of lithium metal parallel to one another on the current collector layer, where N is an integer greater than one; and pressing the N strips of lithium metal against the rolling surface to create a laminated lithium metal anode layer on the current collector layer.

Abstract: A method for bonding a metal electrode layer and a current collector includes supplying a first metal electrode layer, a current collector layer, and a second metal electrode layer for a battery cell between a first roller and a second roller; connecting a power supply to the first roller and the second roller; and supplying current through the first roller, the first metal electrode layer, the current collector layer, and the second metal electrode layer and the second roller to cause joule heating and bonding of the first metal electrode layer, the current collector layer, and the second metal electrode layer.

Abstract: Systems, methods, and apparatuses of a welding system are disclosed and include a first stage of a scanning device for scanning weld parts to generate a three-dimensional (3D) profile of a weld target wherein the 3D profile captures matching imperfections of a meeting together of the set of weld parts when performing the weld operation; and the second stage of a monitoring device to monitor the weld operation and to generate a data of high-resolution measurements of the weld operation; wherein the first stage further includes the monitoring device determining a weld schedule based on the 3D profile, and to adjust the weld schedule while the weld operation progresses to adapt to predicted distortion based on the 3D profile and to sensed distortion; wherein the second stage further includes a plurality of sensors to sense a set of components associated with the weld operation to generate high-resolution data of measurements.

Abstract: A battery cell includes cathode electrodes including cathode electrode coatings arranged on cathode current collectors, and anode electrodes including anode electrode coatings arranged on anode current collectors. The cathode electrodes and the anode electrodes are arranged in a predetermined order in a stack. The cathode current collectors include first external tabs in a first asymmetric position and second external tabs in a second asymmetric position. The first external tabs and the second external tabs of the cathode electrodes are welded to a cathode lead tab. The anode current collectors include first external tabs in a first asymmetric position and second external tabs in a second asymmetric position. The first external tabs and the second external tabs of the anode electrodes are welded to an anode lead tab.

Abstract: A lithium addition system includes: a lithium addition head configured to receive a filament of lithium; and a fill control module configured to: identify a defect in a layer of lithium; actuate an actuator and move the lithium addition head to a location of the defect and vertically above the defect; and apply one of power and energy to the filament thereby (a) at least one of softening, melting, and deforming the filament and (b) depositing lithium from the filament into the defect in the layer of lithium.

Abstract: In various aspects, the present disclosure provides a method of manufacturing an electrode for an electrochemical cell. The method includes contacting a solid electrode material and a substrate at an interface. The method further includes preparing a liquid electrode material at the interface by heating at least a portion of the solid electrode material to a first temperature. The first temperature is greater than or equal to a melting point of the solid electrode material. The method further includes creating a layer of the liquid electrode material on the substrate by moving at least one of the solid electrode material and the substrate with respect to the other of the solid electrode material and the substrate. The method further includes forming the electrode by cooling the liquid electrode material to a second temperature. The second temperature is less than or equal to the melting point.

Abstract: A heating system includes a conveying system configured to transport a plurality of vehicle body-in-whites (BIWs) sequentially through an oven room to cure paint applied in a paint room. A preheating system includes one or more robot arms. A heat source is connected to the one or more robot arms. A controller is configured to control the one or more robot arms based on a position of one of the vehicle BIWs on the conveying system and to position the heat source near or in direct contact with one or more inner components of the one of the vehicle BIWs to heat the one or more inner components prior to the one of the vehicle BIWs entering the oven room.

Abstract: In various aspects, the present disclosure provides a method of manufacturing an electrode for an electrochemical cell. The method includes contacting a solid electrode material and a substrate at an interface. The method further includes preparing a liquid electrode material at the interface by heating at least a portion of the solid electrode material to a first temperature. The first temperature is greater than or equal to a melting point of the solid electrode material. The method further includes creating a layer of the liquid electrode material on the substrate by moving at least one of the solid electrode material and the substrate with respect to the other of the solid electrode material and the substrate. The method further includes forming the electrode by cooling the liquid electrode material to a second temperature. The second temperature is less than or equal to the melting point.

Abstract: A method comprises deforming one or more metal foils of a battery between a punch and a die to form bent metal foils. The one or more bent metal foils are disposed in a foil holding fixture with a battery lead disposed next to the one or more bent metal foils such that a bent portion of the one or more bent metal foils are separated from the battery lead by a distance of 0.1 to 2 millimeters. The one or more bent metal foils are impact welded by causing the foils to impact one another or to impact a battery lead at a velocity of speeds of 300 to 900 meters per second.

Abstract: Disclosed herein is a device for magnetic welding of battery boils comprising a coil holder; where the coil holder comprises one or more electrical coils that are operative to be activated by an electrical current; a foil holding fixture; wherein the foil holding fixture comprises a plurality of arms; wherein each pair of adjacent arms is operative to move towards one another to crimp a plurality of battery foils; and an anvil; wherein the anvil is operative to support a battery tab and the battery foils.