Gm Global Technolgoy Operations, Inc.

Johnson Controls Technology Company

Robert H Dietze

Christopher Brady

Dmitriy Bruder

Robin James

Megan E McGOVERN

Alexandra J Austin

Chih-chang Chen

Robert W Chalfant

Ryan Gergely

Jason A Lupienski

Daniel J Casoli

Mark A Pattok

John D Tompkins

William O Merkle

John James Flannery

Michael M Arvaneh

Wei-Pin Wu

Joseph P Vitale

Robert M Healy

Jeffrey A Lindberg

Jacob W Disbro

Jeffrey R Wells

Tyler J Murphy

Stephanie L Corker

Gene P Emmerich

Edward S Turvene

A multi-level busbar for interconnecting flexible cell tabs within a battery module of a battery electric system, e.g., of a motor vehicle having a traction motor and road wheels, includes first and second busbar surfaces and an elongated step transition. The first busbar surface is arranged at a first level of the busbar and is configured to be welded to a first tab group of the cell tabs. The second busbar surface is arranged at a second level of the busbar, and configured to be welded to a second tab group of the cell tabs. The step transition has a height dimension configured to allow the first and second tab groups to overlap when folded against and welded to the busbar.

Battery electric system with multi-level busbar

A system for transporting a non-Newtonian material. The system includes a storage container configured to store the non-Newtonian material and a dispensing system configured to dispense the non-Newtonian material. A conduit connects the storage container to the dispensing system. The conduit is configured to transport the non-Newtonian material from the storage container to the dispensing system. A pump is configured to pump the non-Newtonian material out of the storage container and through the conduit to the dispensing system. A hanger is configured to support the conduit from a support structure. An acoustic wave generator is along the conduit configured to impart acoustical shear agitation to the non-Newtonian material to reduce viscosity of the non-Newtonian material.

System for transporting non-Newtonian materials using acoustic softening over long distances

A system for measuring effects of vibration on rheometric properties of a fluid sample. The system includes a receptacle configured to hold the fluid sample and receive a probe extending from a rheometric measuring device. A vibration generator is configured to vibrate the fluid sample within the receptacle while the rheometric measuring device measures the rheometric properties of the fluid sample. A vibration control module is configured to control frequency at which the vibration generator vibrates.

Systems and methods for measuring effects of vibration on rheometric properties of a fluid

Presented are metalworking systems for forming metallic workpieces, methods for making/operating such metalworking systems, and battery module cell tabs bent by a multistage cluster-and-bend press. A metalworking system includes a grouping tool and a contouring tool that both align adjacent a workpiece support structure, such as a base plate of a battery module housing buttressing a stack of battery pouch cells. The grouping tool, which may include a first reciprocating plunger or plunger head, presses together a stack of metallic workpieces to thereby form a workpiece set having a first bend profile and a first length. The contouring tool, which may include a second reciprocating plunger or a pair of plunger fingers mounted on the plunger head, is attached to the grouping tool and bends the workpiece set to a second bend profile, distinct from the first bend profile, and a second set length, shorter than the first set length.

Multistage plunger systems and methods for forming battery cell tabs

Presented are metalworking systems for joining metallic workpieces, methods for forming and welding such workpieces, and lithium-ion battery pouch cells with anodized aluminum tabs joined via knurling and laser welding. A method for laser welding abutting sections of a workpiece or stackup of workpieces includes receiving, via a workpiece support frame, one or more metallic workpieces each with a surface having applied thereto a treatment layer. This treatment layer releases a gas during welding. A metalworking device forms a knurl pattern into the workpiece surface with the treatment layer. The knurl pattern includes a network of channels, such as one or more series of mutually parallel, rectilinear vent channels, designed to exhaust therethrough the gas released from a welded section of the treatment layer. A laser welding device thereafter welds a joint region of the surface(s) of the one or more metallic workpiece with the knurl pattern.

Welding systems and methods with knurled weld interfaces for metallic workpieces

Presented are metalworking systems for forming metallic workpieces, methods for making such workpieces and methods for operating such systems, and battery cell tabs bent by a multistage plunger press. A metalworking system includes a plunger fixture that mounts adjacent metallic workpieces, and a plunger head movably mounted to the plunger fixture to move between activated and deactivated positions. A first row of plunger fingers is mounted to the plunger head and moves in one direction to press against and bend one metallic workpiece a predefined bend angle. Likewise, a second row of plunger fingers is mounted to the plunger head and moves in an opposite direction to press against and bend another metallic workpiece another predefined bend angle. The plunger head then moves to the activated position, in tandem with the plunger fingers bending the metallic workpieces, to cause the plunger fingers to bend the workpieces additional respective bend angles.

Multistage plunger press systems and methods with interlocking fingers for forming battery cell tabs

A tooling system is configured to align and assemble a battery module having a plurality of battery cells arranged in a stack. Each battery cell has a flexible electrical terminal arranged along a respective terminal axis, and wherein the terminal axes are parallel to one another. The system includes a tooling fixture defining at least one Y-shape slit having a V-collector culminating in a slot arranged along a slot axis. Each V-collector is configured to capture the terminals of at least two battery cells. Each slot is configured to group the captured terminals when the slot axis is parallel to the terminal axes and the fixture engages the battery module. The system also includes a mechanism configured to apply a first force to the fixture along the slot axis to engage the battery module with the fixture. The mechanism thereby groups and aligns the captured terminals within the slot.

Tooling and method for alignment and assembly of battery module

Presented are metalworking systems for forming metallic workpieces, methods for making/operating such systems, and battery packs with cell terminals bent by a two-stage plunger press. A metalworking system includes a first plunger with a plunger cavity extending through the first plunger's body, and one or more die cavities recessed into the first plunger's contact face. The die cavity includes one surface that contacts and bends a first workpiece a first angle, and another surface that contacts and bends a second workpiece a second angle. A second plunger includes one or more die cavities recessed into the second plunger's contact face. This die cavity includes one surface that contacts and bends the first workpiece a third angle, and another surface that contacts and bends the second workpiece a fourth angle. The second plunger passes through the plunger cavity such that the first and second plungers bend the metallic workpieces in tandem.

Two-stage plunger press systems and methods for forming battery cell tabs

A retention socket is configured to hold a non-ferrous metallic fastener and includes a socket body defining a cavity shaped to receive a head of the non-ferrous metallic fastener. The retention socket further includes a mechanical retaining feature coupled to the socket body to removably couple the non-ferrous metallic fastener to the socket body without the aid of magnetic forces.

Non-ferrous fastener retention socket

Tooling systems and methods may be employed for installing a plurality of visually similar threaded fasteners to a plurality of assemblies. Each of the assemblies may have one or more threaded mating surfaces configured to receive different types of threaded fasteners, e.g., formed of different materials. The tooling system may include a tool(s) having a drive surface configured to install a threaded fastener by relative rotation of a gripping feature of the fastener with respect to a corresponding mating thread, each tool having a sensor disposed adjacent the drive surface and configured to detect a presence of the first material when a gripping feature of the one of the threaded fasteners of the first fastener type is positioned on the drive surface. The tooling system may also include a controller configured to determine the type of the selected threaded fastener based upon the sensor.

Fastener error proofing tool

A system for evaluating battery connection quality in one or more battery modules of a battery assembly includes a battery testing unit having a housing including an upper surface and a lower surface. A plurality of testing modules are disposed on the lower surface of the housing to communicate with and electrically contact the one or more battery modules of the battery assembly. The plurality of testing modules each include at least one connector extending from a lower surface of the testing module and at least one contact disposed on one or more side surfaces of the testing module. A controller is in electrical communication with the at least one connector and at least one contacts to simultaneously evaluate voltage and resistance measurements of the one or more battery modules of the battery assembly.

System for evaluating battery connection quality

A method of assembling a battery assembly includes forming battery packs, each pack including battery cells and cooling passages extending along a length of the pack, connecting terminals of each pack to a dc source and charging each pack to a desired state of charge, installing battery packs on a tray located on an automatically guided cart, using the cart to carry the battery assembly to locations where method steps are performed including performing testing for fluid leaks in a cooling circuit comprising interconnected passages of each pack on the tray and installing electric circuits in the assembly.

Method of assembling electric storage battery packs

A vehicle seat assembly having a seat back which pivots during a rear impact vehicle collision in Such a manner that the upper end of the seat back rotates foreword. The pivoting seat back includes a releasable latch mechanism to hold the seat back frame fixed in a predetermined position about a pivot axis. The latch mechanism is releasable by inertia forces in response to a rear vehicle collision, to release the latch member and free the seat back frame for rotation about the pivot axis.

Growing community of inventors

Brighton, MI, United States of America

Robert H Dietze