Abstract: Particles of active electrode material for a lithium secondary battery are coated with a precursor material which is either a carbon-based polymer or a metal and oxygen containing compound. The precursor material-coated particles are injected into a gas stream and momentarily exposed to an atmospheric plasma at a predetermined energy level and temperature up to about 3500° C. The plasma treatment converts (i) the carbon polymer to submicron size carbon particles or (ii) the metal compound to metal oxide particles on the surfaces of the particles of electrode material. In preferred embodiments of the invention the plasma treated coated active electrode material particles are carried by the gas stream and deposited onto an electrode material bearing substrate for a lithium battery cell.

Abstract: Lithium-ion battery cells and a lithium-ion utilizing capacitor cells are placed spaced-apart in a common container and infiltrated with a common lithium-ion transporting, liquid electrolyte. The lithium-ion-utilizing capacitor and lithium-ion cell battery are combined such that their respective electrodes may be electrically connected, either in series or parallel connection for energy storage and management in an automotive vehicle or other electrical power supply application.

Abstract: An atmospheric plasma spray device is used to direct a stream of plasma-heated, particulate, lithium battery electrode materials to form a porous layer of the electrode particles on a surface of a compatible current collector metal foil. Subsequently, a non-plasma spray device is used to direct a stream of droplets of an aqueous solution of a polymeric binder material onto and into the porous layer of electrode particles. Water evaporates from the droplets of binder solution as the droplets infiltrate the porous electrode material and coat the electrode particles and current collector surface. When the water (or other solvent) has evaporated from the dispersed droplets of polymer material, the polymer binder bonds the particles to each other and to the current collector surface. The polymer spray may immediately follow the deposition of the electrode particles, or follow later, even at a downstream spray location.

Abstract: Atmospheric plasma spray devices and methods are used in the making of the electrodes for both a lithium-ion battery and a lithium-ion utilizing capacitor structure, which are to be placed in a common container and infiltrated with a common lithium-ion transporting, liquid electrolyte. The lithium-ion-utilizing capacitor and lithium-ion cell battery are combined such that the respective electrodes may be electrically connected, either in series or parallel connection for in energy storage and management in an automotive vehicle or other electrical power supply application.

Abstract: Particles of active electrode material for a lithium-ion cell are suspended in an atmospheric plasma-activated gas stream and deposited on a surface of a metal current collector foil having a surface film of an oxide of the metal. The metal oxide film-containing surface of the current collector is pre-coated with a thin layer of an electrically conductive organic polymer composition that serves as a bonding surface for the plasma-applied particles of electrode material. For example, a non-conductive polymer (such as polyvinylidene difluoride) may be filled with carbon particles or copper particles. The polymer layer is typically only a few micrometers in thickness and composed to be compatible with the plasma-applied electrode material particles and to conduct electrons between the oxide film-coated, metal current collector and the deposited electrode layer.

Abstract: Particles of active electrode material for a lithium secondary battery are coated with a precursor material which is either a carbon-based polymer or a metal and oxygen containing compound. The precursor material-coated particles are injected into a gas stream and momentarily exposed to an atmospheric plasma at a predetermined energy level and temperature up to about 3500° C. The plasma treatment converts (i) the carbon polymer to submicron size carbon particles or (ii) the metal compound to metal oxide particles on the surfaces of the particles of electrode material. In preferred embodiments of the invention the plasma treated coated active electrode material particles are carried by the gas stream and deposited onto an electrode material bearing substrate for a lithium battery cell.

Abstract: Multi-layer lithium-ion cell units for lithium batteries are made using multiple stages of atmospheric plasma spray depositing devices. A suitable substrate layer is conveyed past the respective plasma spray devices to form, in a predetermined sequence, a current collector layer, a particulate electrode material layer, a porous separator layer for a liquid lithium-ion conducting electrolyte, a layer of particulate material for an opposing electrode, and a current collector film for the electrode material. The plasma deposition process allows flexibility and economy in making layered lithium-ion cell units. For example, the multistage process may be conducted in a continuous processing, multi-stage plasma deposition line in which one or more multi-layer cell units may be formed in the line.

Abstract: Aluminum alloy workpieces and/or magnesium alloy workpieces are joined in a solid state weld by use of a reactive material placed, in a suitable form, at the joining surfaces. Joining surfaces of the workpieces are pressed against the interposed reactive material and heated. The reactive material alloys or reacts with the workpiece surfaces consuming some of the surface material in forming a reaction product comprising a low melting liquid that removes oxide films and other surface impediments to a welded bond across the interface. Further pressure is applied to expel the reaction product and to join the workpiece surfaces in a solid state weld bond.

Abstract: Layers of particles of positive or negative electrode materials for lithium-secondary cells are deposited on porous separator layers or current collector films using atmospheric plasma practices for the deposition of the electrode material particles. Before the deposition step, the non-metallic electrode material particles are coated with smaller particles of an elemental metal. The elemental metal is compatible with the particulate electrode material in the operation of the electrode and the metal particles are partially melted during the atmospheric deposition step to bond the electrode material particles to the substrate and to each other in a porous layer for infiltration with a liquid lithium ion-containing electrolyte. And the metal coating on the particles provides suitable electrical conductivity to the electrode layer during cell operation.

Abstract: A first atmospheric plasma producing nozzle is used to direct a gas-borne stream of plasma heated and activated particles of lithium battery electrode material for deposition on a surface of lithium cell member, such as a separator or current collector foil. A second atmospheric plasma producing nozzle is used to direct a gas-borne stream of plasma heated and activated metal particles at the same surface area being coated with the stream of electrode material particles. The two plasma streams are combined at the cell member surface to form a layer of electrically-conductive metal-bonded particles of electrode material. The use of multiple atmospheric plasma streams is useful in making thin, efficient, and lower cost electrode structures for lithium batteries.

Abstract: A method is provided for welding together a tubular member of a first metal and a tubular member of a second metal that is dissimilar to the first metal. The method includes making a transition attachment by friction welding together end-to-end a first end of a rod of the first metal with a first end of a rod of the second metal. An arc weld welds together a second end of the rod of the first metal with the tubular member of the first metal. And another arc weld welds together a second end of the rod of the second metal to the tubular member of the second metal.

Abstract: Lithium-ion battery cells and a lithium-ion utilizing capacitor cells are placed spaced-apart in a common container and infiltrated with a common lithium-ion transporting, liquid electrolyte. The lithium-ion-utilizing capacitor and lithium-ion cell battery are combined such that their respective electrodes may be electrically connected, either in series or parallel connection for energy storage and management in an automotive vehicle or other electrical power supply application.

Abstract: The manufacture of electrode members for lithium-ion electrochemical cells and batteries is more efficient using an atmospheric plasma stream in carrying, heating, and directing current collector and electrode materials for deposition on thin sheet substrates. Particles of conductive metals are heated and partially melted in the plasma and deposited as current collector films for active electrodes (and reference electrodes) at relatively low temperatures (<100° C.) on separator sheets. Particles of lithium-ion accepting and releasing electrode materials are combined with smaller portions of conductive metals for plasma heating and deposition on current collector layers in forming positive and negative electrodes for lithium-ion cells. Such use of the atmospheric plasma avoids the need for the use of organic binders and wet deposition practices in electrode layer manufacture, and enables the deposition of thicker, lower stress layers of active electrode materials for higher cell capacity and power.

Abstract: A method is disclosed for making a lithium-ion electrochemical cell comprising elements of the lithium-ion electrochemical cell contained within an aluminum alloy or magnesium alloy single-cell container. External surfaces of the container are coated for resistance to water-based corrosion. Rolled or folded layers of anode, cathode, and separator elements of the lithium-ion cell are placed in the aluminum or magnesium alloy container. And, with the placed elements of the lithium-ion cell in the container, and during one or more following steps of a manufacturing assembly process of the lithium-ion cell, an atmospheric pressure plasma stream, initially comprising hexamethyldisiloxane, is applied to external surfaces of the aluminum alloy or magnesium alloy container to form a silicone polymer coating on the surfaces that protects the container from water-based corrosion. The method is useful in forming batteries for automotive vehicles exposed to salt water environments.

Abstract: Aluminum alloy workpieces and/or magnesium alloy workpieces are joined in a solid state weld by use of a reactive material placed, in a suitable form, at the joining surfaces. Joining surfaces of the workpieces are pressed against the interposed reactive material and heated. The reactive material alloys or reacts with the workpiece surfaces consuming some of the surface material in forming a reaction product comprising a low melting liquid that removes oxide films and other surface impediments to a welded bond across the interface. Further pressure is applied to expel the reaction product and to join the workpiece surfaces in a solid state weld bond.

Abstract: Aluminum alloy workpieces and/or magnesium alloy workpieces are joined in a solid state weld by use of a reactive material placed, in a suitable form, at the joining surfaces. Joining surfaces of the workpieces are pressed against the interposed reactive material and heated. The reactive material alloys or reacts with the workpiece surfaces consuming some of the surface material in forming a reaction product comprising a low melting liquid that removes oxide films and other surface impediments to a welded bond across the interface. Further pressure is applied to expel the reaction product and to join the workpiece surfaces in a solid state weld bond.

Abstract: A method of welding two or more workpieces employing a motion-controlled electrode that reduces temperature and residual stresses at a workpiece-to-electrode interface is disclosed. During a first period of time, a first electrode force is applied to the workpieces to be welded, and a weld current is applied that causes heating of an associated workpiece-to-workpiece faying surface, the first electrode force being applied at a first electrode stroke. A temperature of the faying surface indicative of a weld nugget formation thereat is determined, and in response thereto the electrode force is reduced to a second level during a second period of time while maintaining a constant electrode stroke. During a third period of time, the electrode force is further reduced to a third level while simultaneously reducing the electrode stroke to a second level. Welding is stopped after the third period of time, resulting in a weld joint having reduced residual stresses and reduced likelihood of stress crack formation.

Abstract: Methods of reducing corrosion between magnesium and another metal are disclosed herein. In one method, a corrosion protection material is cold sprayed at an interface formed between the magnesium and the other metal, the corrosion protection material including magnesium. In another method, a cladding layer is applied to heat affected areas of the magnesium and/or the other metal, at a welded joint, or combinations thereof.

Abstract: An apparatus and method is provided for hemming together a pair of panels and immediately sealing the hemmed joint against the intrusion of moisture. A tool mount is attached to a multi-axis manipulator such as a robot for moving the tool mount along the edge portions of the panels. A hemming roller is mounted on the tool mount and adapted to be moved along the edge portions of the panels by the multi axis manipulator to fold the flanged edge portion of the outer panel onto the edge portion of inner panel as the tool mount traverses the edge portions of the panels. A sealing mechanism is mounted on the tool mount adjacent to the hemming roller to seal the hemmed joint immediately after the flanged edge portion is folded onto the inner panel. The sealing mechanism may be a dispenser of adhesive sealer or a friction stir welder.

Abstract: The present invention provides an apparatus and improved method of friction stir spot welding that assures a predetermined bottom thickness and a reduction in variation in a series of resultant spot welds. The advantage of the present invention lies in that the plunge distance is controlled from the top plane of the anvil against which the bottom thickness is specified, and systematically adjusted to account for changing system parameters, such as, but not limited to, deflection and thermal expansion of the weld gun. The present invention also provides for improved and controlled weld quality through implementation of a dwell operation or dwell operations, whereby weld heat input is manipulated by causing the weld tool to dwell in a dwell region or at a desired depth or depths within the workpiece(s) for a predetermined time interval to achieve desired mechanical properties of the resultant weld joint.