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    Method of making a battery cell including clamping, tapering, trimming and ultrasonic welding of electrode foils
    1.
    发明授权
    Method of making a battery cell including clamping, tapering, trimming and ultrasonic welding of electrode foils 有权

    公开(公告)号：US12136747B2

    公开(公告)日：2024-11-05

    申请号：US17868887

    申请日：2022-07-20

    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

    Inventor： Wayne W. Cai ,  Thomas Alumoottil ,  Jennifer T. Bracey ,  Teresa J. Rinker ,  Cammi L. Siu

    IPC: H01M50/536 ,  B23K20/10 ,  B23K101/36

    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.

    Battery module with resistance-welded senseline tabs and method of manufacturing the same
    2.
    发明授权
    Battery module with resistance-welded senseline tabs and method of manufacturing the same 有权

    公开(公告)号：US10530019B2

    公开(公告)日：2020-01-07

    申请号：US15341392

    申请日：2016-11-02

    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

    Inventor： Evan J. Dawley ,  Wayne W. Cai

    IPC: H01M10/48 ,  H01M2/20

    Abstract: A battery module includes a battery cell, a bus bar, and a multilayered cell sense flex circuit having a senseline tab containing a portion of a senseline. The flex circuit determines a battery cell voltage. The bus bar has surface projections, possibly with a variable height and/or width, such that the bus bar penetrates into the tab at least as far as the senseline. Adhesive material may be used on the welded joint. A method of manufacturing the battery module includes forming, in the bus bar, one or more surface projections, e.g., multiple projections having the variable height and/or width, positioning a senseline tab of the flex circuit adjacent to such projections, and joining the tab to the surface projections such that the projections penetrate at least partially into the flex circuit at least as far as the senseline.

    Automatic monitoring of vibration welding equipment
    3.
    发明授权
    Automatic monitoring of vibration welding equipment 有权
    自动监测振动焊接设备

    公开(公告)号：US08858742B2

    公开(公告)日：2014-10-14

    申请号：US14065801

    申请日：2013-10-29

    Applicant: GM Global Technology Operations LLC

    Inventor： John Patrick Spicer ,  Debejyo Chakraborty ,  Michael Anthony Wincek ,  Hui Wang ,  Jeffrey A. Abell ,  Jennifer Bracey ,  Wayne W. Cai

    IPC: B32B37/00 ,  B29C65/08 ,  B06B3/00 ,  B29C65/00

    CPC classification number: B32B37/00 ,  B06B3/00 ,  B23K20/10 ,  B23K20/106 ,  B23K20/26 ,  B29C65/08 ,  B29C66/90 ,  B29C66/9121

    Abstract: A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host device, a check station, and a robot. The robot moves the horn and anvil via an arm to the check station. Sensors, e.g., temperature sensors, are positioned with respect to the welding equipment. Additional sensors are positioned with respect to the check station, including a pressure-sensitive array. The host device, which monitors a condition of the welding equipment, measures signals via the sensors positioned with respect to the welding equipment when the horn is actively forming a weld. The robot moves the horn and anvil to the check station, activates the check station sensors at the check station, and determines a condition of the welding equipment by processing the received signals. Acoustic, force, temperature, displacement, amplitude, and/or attitude/gyroscopic sensors may be used.

    Abstract translation: 振动焊接系统包括具有焊接喇叭和砧座的振动焊接设备，主机设备，检查站和机器人。 机器人通过手臂将喇叭和砧座移动到检查站。 传感器，例如温度传感器，相对于焊接设备定位。 附加传感器相对于检查站定位，包括压敏阵列。 监测焊接设备状况的主机设备，当喇叭主动形成焊缝时，通过相对于焊接设备定位的传感器测量信号。 机器人将喇叭和砧座移动到检查站，激活检查站的检查站传感器，并通过处理接收到的信号来确定焊接设备的状况。 可以使用声学，力，温度，位移，幅度和/或姿态/陀螺仪传感器。

    METHOD AND APPARATUS FOR EVALUATING AN ULTRASONIC WELD JUNCTION
    4.
    发明申请
    METHOD AND APPARATUS FOR EVALUATING AN ULTRASONIC WELD JUNCTION 审中-公开

    公开(公告)号：US20190152001A1

    公开(公告)日：2019-05-23

    申请号：US16251755

    申请日：2019-01-18

    Applicant: GM Global Technology Operations LLC

    Inventor： Wayne W. Cai ,  Debejyo Chakraborty ,  Qian Lin ,  John M. Moote ,  Anthony Ottomano ,  Teresa J. Rinker

    IPC: B23K31/12 ,  G01R31/36 ,  G01N25/72 ,  G01N27/416

    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.

    BATTERY MODULE WITH RESISTANCE-WELDED SENSELINE TABS AND METHOD OF MANUFACTURING THE SAME
    6.
    发明申请
    BATTERY MODULE WITH RESISTANCE-WELDED SENSELINE TABS AND METHOD OF MANUFACTURING THE SAME 审中-公开

    公开(公告)号：US20180123188A1

    公开(公告)日：2018-05-03

    申请号：US15341392

    申请日：2016-11-02

    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

    Inventor： Evan J. Dawley ,  Wayne W. Cai

    IPC: H01M10/48 ,  H01M2/20

    CPC classification number: H01M10/48 ,  H01M2/1077 ,  H01M2/202 ,  H01M2/206 ,  H01M10/482 ,  H01M2220/20

    Abstract: A battery module includes a battery cell, a bus bar, and a multilayered cell sense flex circuit having a senseline tab containing a portion of a senseline. The flex circuit determines a battery cell voltage. The bus bar has surface projections, possibly with a variable height and/or width, such that the bus bar penetrates into the tab at least as far as the senseline. Adhesive material may be used on the welded joint. A method of manufacturing the battery module includes forming, in the bus bar, one or more surface projections, e.g., multiple projections having the variable height and/or width, positioning a senseline tab of the flex circuit adjacent to such projections, and joining the tab to the surface projections such that the projections penetrate at least partially into the flex circuit at least as far as the senseline.

    VIBRATION WELDING SYSTEM AND METHOD
    7.
    发明申请
    VIBRATION WELDING SYSTEM AND METHOD 审中-公开

    公开(公告)号：US20180036832A1

    公开(公告)日：2018-02-08

    申请号：US15228412

    申请日：2016-08-04

    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

    Inventor： Teresa J. Rinker ,  Wayne W. Cai ,  Nicholas W. Pinto ,  Michael P. Balogh

    IPC: B23K20/00 ,  B23K20/10

    CPC classification number: B23K20/004 ,  B23K20/106 ,  B23K2101/32 ,  B23K2101/38

    Abstract: A vibration welding system for joining a wire to a substrate includes a welding pad attached to a sonotrode and an anvil. The welding pad includes first energy directors that are disposed in a first region and second energy directors that are disposed in a second region. A channel is formed between the substrate and the first energy directors when the second energy directors are in contact with the substrate. The channel is configured to accommodate a portion of the wire, and has a depth that is less than a cross-sectional diameter of the wire. The wire and the substrate are clamped between the welding pad and the anvil during operation of the sonotrode. The first energy directors urge the wire towards the substrate during the operation of the sonotrode to effect joining of the wire to the substrate.

    Automatic monitoring of the alignment and wear of vibration welding equipment
    9.
    发明授权
    Automatic monitoring of the alignment and wear of vibration welding equipment 有权

    公开(公告)号：US10191471B2

    公开(公告)日：2019-01-29

    申请号：US15486799

    申请日：2017-04-13

    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

    Inventor： John Patrick Spicer ,  Wayne W. Cai ,  Debejyo Chakraborty ,  Keith Mink

    IPC: G05B19/4065 ,  B23K20/26 ,  B23K31/12 ,  B23K20/10 ,  B23K101/00 ,  B23K101/36

    Abstract: A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host machine, a check station, and a welding robot. At least one displacement sensor is positioned with respect to one of the welding equipment and the check station. The robot moves the horn and anvil via an arm to the check station, when a threshold condition is met, i.e., a predetermined amount of time has elapsed or a predetermined number of welds have been completed. The robot moves the horn and anvil to the check station, activates the at least one displacement sensor, at the check station, and determines a status condition of the welding equipment by processing the received signals. The status condition may be one of the alignment of the vibration welding equipment and the wear or degradation of the vibration welding equipment.

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