Patent Publication Number: US-2022231486-A1

Title: Bus bars for printed structural electric battery modules

Description:
CROSS REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of U.S. Provisional Application Ser. No. 63/139,295, entitled “BUS BARS FOR PRINTED STRUCTURAL CELLULAR ELECTRIC BATTERY MODULES” and filed on Jan. 19, 2021, the disclosure of which is expressly incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     Field 
     The present disclosure relates generally to techniques for co-printing bus bars for printed structural energy storage modules using additively manufactured parts and techniques. 
     Background 
     Three-dimensional (3-D) printing, also referred to as additive manufacturing (AM), presents new opportunities to more efficiently build structures, such as automobiles, aircraft, boats, motorcycles, busses, trains and the like. Applying AM processes to industries that produce these products has proven to produce a structurally more efficient transport structure. For example, an automobile produced using 3-D printed components can be made stronger, lighter, and consequently, more fuel efficient. Moreover, AM enables manufacturers to 3-D print parts that are much more complex and that are equipped with more advanced features and capabilities than parts made via traditional machining and casting techniques. 
     Despite these recent advances, a number of obstacles remain with respect to the practical implementation of AM techniques in transport structures and other mechanized assemblies. For instance, regardless of whether AM is used to produce various components of such devices, manufacturers typically rely on labor-intensive and expensive techniques such as welding, riveting, etc., to join components together, such as nodes used in a transport structure. The deficiencies associated with welding and similar techniques are equally applicable to components, such as a vehicle gear case, that are currently too large to 3-D print in a single AM step. A given 3-D printer is usually limited to rendering objects having a finite size, often dictated by the available surface area of the 3-D printer&#39;s build plate and the allowable volume the printer can accommodate. In these instances, manufacturers are often relegated to building the component using the traditional, expensive and time-consuming machining techniques. Alternatively, manufacturers may 3-D print a number of subcomponents and combine them to form a complete, functional component or assembly. 
     Thus, the current manufacturing techniques are unable to manufacture primary structures of high complexity and varied shapes such that they can enable for an optimized load sharing throughout a vehicle and fail to resolve the problem of vehicles with large mass. 
     SUMMARY 
     Several aspects and techniques for co-printing bus bars for printed structural energy storage modules will be described more fully hereinafter with reference to three-dimensional (3-D) printing techniques. 
     An apparatus in accordance with an aspect of the present disclosure comprises a first component configured to be a primary structure of a vehicle, the first component co-printed with a first electrical conductive path, the first electrical conductive path configured to be connected to a second electrical conductive path of a second component of the vehicle, wherein the first electrical conductive path and the second electrical conductive are configured to enable electricity transmission. 
     In certain aspects, the first component of such an apparatus comprises at least a tongue structure configured to mate with a corresponding groove structure of the second component, wherein the first electrical conductive path passes through a portion of the tongue structure of the first component. In certain aspects, the first component comprise a groove structure configured to mate with a corresponding tongue structure of the second component wherein the second electrical conductive path passes through a portion of the tongue structure of the second component. 
     In certain aspects, the first component of such an apparatus is co-printed with a first set of supports, each support of the first set of supports is connected to a portion of the first electrical conductive path. 
     In certain aspects, the first component of such an apparatus is configured to receive at least a portion of a first energy storage module. In certain aspects, the first electrical conductive path is configured to be connected to the first energy storage module. 
     In certain aspects, such an apparatus further optionally includes an electrical insulator between the first conductive path and the first component. In certain aspects, the first electrical conductive path comprises a bus bar. 
     It will be understood that other aspects of co-printing bus bars for printed structural energy storage modules will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only several embodiments by way of illustration. As will be appreciated by those skilled in the art, the co-printing bus bars for printed structural energy storage modules can be realized with other embodiments without departing from the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various aspects of apparatuses and methods for co-printing bus bars for printed structural energy storage modules will now be presented in the detailed description by way of example, and not by way of limitation, in the accompanying drawings, wherein: 
         FIGS. 1A-1D  illustrate respective side views of a 3-D printer system, in accordance with various aspects of the present disclosure; 
         FIG. 1E  illustrates a functional block diagram of a 3-D printer system, in accordance with various aspects of the present disclosure; 
         FIG. 2  shows a perspective view illustrating an additively manufactured node-node joint, in accordance with various aspects of the present disclosure; 
         FIG. 3  shows a cross-sectional view illustrating the node-node joint of  FIG. 1 , in accordance with various aspects of the present disclosure; 
         FIG. 4  illustrates a perspective cross-sectional view of a node, in accordance with various aspects of the present disclosure; 
         FIGS. 5A-5B  illustrates a perspective view of a node with co-printed bus bas, in accordance with various aspects of the present disclosure; 
         FIG. 6  illustrates a cross-sectional view illustrating bus bar to bus bar joint, in accordance with various aspects of the present disclosure; 
         FIG. 7  illustrates a cross-sectional view of a co-printed bus bar connected with an energy storage module in a node, in accordance with various aspects of the present disclosure; 
         FIG. 8  illustrates a perspective view of bus bars connected with energy storage modules, in accordance with various aspects of the present disclosure; and 
         FIG. 9  illustrates bus bars connected with energy storage modules and other components of a vehicle, in accordance with various aspects of the present disclosure. 
         FIG. 10  is a flowchart illustrating an example method in accordance with various aspects of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The detailed description set forth below in connection with the drawings is intended to provide a description of exemplary embodiments of co-printing bus bars for printed structural energy storage modules, and it is not intended to represent the only embodiments in which the invention may be practiced. The term “exemplary” used throughout this disclosure means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments presented in this disclosure. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure that fully conveys the scope of the invention to those skilled in the art. However, the invention may be practiced without these specific details. In some instances, well-known structures and components may be shown in block diagram form, or omitted entirely, in order to avoid obscuring the various concepts presented throughout this disclosure. 
     As described above, energy storage modules, for example, batteries, used in vehicles, and particularly, in electrical vehicles account for a large amount of total mass. The present disclosure is generally directed to techniques for additive manufacturing that allows for energy storage modules to be integrated into primary structures. The primary structures may be formed by joining nodes as described herein. For example, the primary structures and/or nodes may be additively manufactured and/or configured to receive the energy storage modules. While configuring the primary structures to receive energy storage modules may reduce mass of the vehicle, however the total mass of the vehicle may not be fully optimized unless the electrical conductive paths connecting the energy storage modules to other electrical components of the vehicle are also manufactured in a manner without requiring additional support structures to hold the electrical conductive path. Accordingly, the present disclosure is also directed to techniques for using additive manufacturing to co-print a primary structure and/or a portion of the primary with a bus bar. 
     The techniques described in the present disclosure allow for the bus bars to be co-printed in various shapes such that the bus bars can successfully connect individual energy storage modules in different primary structures. The techniques described in the present disclosure allow for the bus bars to connect and/or couple individual energy storage modules into a pack through various series and/or parallel connections with the energy storage modules. Thus, the techniques described in the present disclosure allow for a desired level of system voltage to be retained while reducing and spreading the mass of the vehicle more evenly throughout a vehicle. 
     The use of additive manufacturing in the context of joining two or more parts provides significant flexibility and cost saving benefits that enable manufacturers of mechanical structures and mechanized assemblies to manufacture parts with complex geometries at a lower cost to the consumer. The joining techniques described in the foregoing relate to a process for connecting AM parts and/or commercial off the shelf (COTS) components. AM parts are printed three-dimensional (3-D) parts that are printed by adding layer upon layer of a material based on a preprogramed design. The parts described in the foregoing may be parts used to assemble a transport structure such as an automobile. However, those skilled in the art will appreciate that the manufactured parts may be used to assemble other complex mechanical products such as vehicles, trucks, trains, motorcycles, boats, aircraft, and the like, and other mechanized assemblies, without departing from the scope of the invention. 
     A node is an example of an AM part. A node may be any 3-D printed part that includes a socket or other mechanism (e.g., a feature to accept these parts) for accepting a component such as a tube and/or a panel. The node may have internal features configured to accept a particular type of component. Alternatively or conjunctively, the node may be shaped to accept a particular type of component. A node, in some embodiments of this disclosure may have internal features for positioning a component in the node&#39;s socket. However, as a person having ordinary skill in the art will appreciate, a node may utilize any feature comprising a variety of geometries to accept any variety of components without departing from the scope of the disclosure. For example, certain nodes may include simple insets, grooves or indentations for accepting other structures, which may be further bound via adhesives, fasteners or other mechanisms. 
     Nodes as described herein may further include structures for joining tubes, panels, and other components for use in a transport structure or other mechanical assembly. For example, nodes may include joints that may act as an intersecting points for two or more panels, connecting tubes, or other structures. To this end, the nodes may be configured with apertures or insets configured to receive such other structures such that the structures are fit securely at the node. Nodes may join connecting tubes to form a space frame vehicle chassis. Nodes may also be used to join internal or external panels and other structures. In many cases, individual nodes may need to be joined together to accomplish their intended objectives in enabling construction of the above described structures. Various such joining techniques are described below. 
       FIGS. 1A-D  illustrate respective side views of an exemplary 3-D printer system. 
     In this example, the 3-D printer system is a powder-bed fusion (PBF) system  100 . 
       FIGS. 1A-D  show PBF system  100  during different stages of operation. The particular embodiment illustrated in  FIGS. 1A-D  is one of many suitable examples of a PBF system employing principles of this disclosure. It should also be noted that elements of  FIGS. 1A-D  and the other figures in this disclosure are not necessarily drawn to scale, but may be drawn larger or smaller for the purpose of better illustration of concepts described herein. PBF system  100  can include a depositor  101  that can deposit each layer of metal powder, an energy beam source  103  that can generate an energy beam, a deflector  105  that can apply the energy beam to fuse the powder material, and a build plate  107  that can support one or more build pieces, such as a build piece  109 . Although the terms “fuse” and/or “fusing” are used to describe the mechanical coupling of the powder particles, other mechanical actions, e.g., sintering, melting, and/or other electrical, mechanical, electromechanical, electrochemical, and/or chemical coupling methods are envisioned as being within the scope of the present disclosure. 
     PBF system  100  can also include a build floor  111  positioned within a powder bed receptacle. The walls of the powder bed receptacle  112  generally define the boundaries of the powder bed receptacle, which is sandwiched between the walls  112  from the side and abuts a portion of the build floor  111  below. Build floor  111  can progressively lower build plate  107  so that depositor  101  can deposit a next layer. The entire mechanism may reside in a chamber  113  that can enclose the other components, thereby protecting the equipment, enabling atmospheric and temperature regulation and mitigating contamination risks. Depositor  101  can include a hopper  115  that contains a powder  117 , such as a metal powder, and a leveler  119  that can level the top of each layer of deposited powder. 
     Referring specifically to  FIG. 1A , this figure shows PBF system  100  after a slice of build piece  109  has been fused, but before the next layer of powder has been deposited. In fact,  FIG. 1A  illustrates a time at which PBF system  100  has already deposited and fused slices in multiple layers, e.g., 150 layers, to form the current state of build piece  109 , e.g., formed of 150 slices. The multiple layers already deposited have created a powder bed  121 , which includes powder that was deposited but not fused. 
       FIG. 1B  shows PBF system  100  at a stage in which build floor  111  can lower by a powder layer thickness  123 . The lowering of build floor  111  causes build piece  109  and powder bed  121  to drop by powder layer thickness  123 , so that the top of the build piece and powder bed are lower than the top of powder bed receptacle wall  112  by an amount equal to the powder layer thickness. In this way, for example, a space with a consistent thickness equal to powder layer thickness  123  can be created over the tops of build piece  109  and powder bed  121 . 
       FIG. 1C  shows PBF system  100  at a stage in which depositor  101  is positioned to deposit powder  117  in a space created over the top surfaces of build piece  109  and powder bed  121  and bounded by powder bed receptacle walls  112 . In this example, depositor  101  progressively moves over the defined space while releasing powder  117  from hopper  115 . Leveler  119  can level the released powder to form a powder layer  125  that has a thickness substantially equal to the powder layer thickness  123  (see  FIG. 1B ). Thus, the powder in a PBF system can be supported by a powder material support structure, which can include, for example, a build plate  107 , a build floor  111 , a build piece  109 , walls  112 , and the like. It should be noted that the illustrated thickness of powder layer  125  (i.e., powder layer thickness  123  ( FIG. 1B )) is greater than an actual thickness used for the example involving 150 previously-deposited layers discussed above with reference to  FIG. 1A . 
       FIG. 1D  shows PBF system  100  at a stage in which, following the deposition of powder layer  125  ( FIG. 1C ), energy beam source  103  generates an energy beam  127  and deflector  105  applies the energy beam to fuse the next slice in build piece  109 . In various exemplary embodiments, energy beam source  103  can be an electron beam source, in which case energy beam  127  constitutes an electron beam. Deflector  105  can include deflection plates that can generate an electric field or a magnetic field that selectively deflects the electron beam to cause the electron beam to scan across areas designated to be fused. In various embodiments, energy beam source  103  can be a laser, in which case energy beam  127  is a laser beam. Deflector  105  can include an optical system that uses reflection and/or refraction to manipulate the laser beam to scan selected areas to be fused. 
     In various embodiments, the deflector  105  can include one or more gimbals and actuators that can rotate and/or translate the energy beam source to position the energy beam. In various embodiments, energy beam source  103  and/or deflector  105  can modulate the energy beam, e.g., turn the energy beam on and off as the deflector scans so that the energy beam is applied only in the appropriate areas of the powder layer. For example, in various embodiments, the energy beam can be modulated by a digital signal processor (DSP). 
       FIG. 1E  illustrates a functional block diagram of a 3-D printer system in accordance with an aspect of the present disclosure. 
     In an aspect of the present disclosure, control devices and/or elements, including computer software, may be coupled to PDF system  100  to control one or more components within PDF system  100 . Such a device may be a computer  150 , which may include one or more components that may assist in the control of PDF system  100 . Computer  150  may communicate with a PDF system  100 , and/or other AM systems, via one or more interfaces  151 . The computer  150  and/or interface  151  are examples of devices that may be configured to implement the various methods described herein, that may assist in controlling PDF system  100  and/or other AM systems. 
     In an aspect of the present disclosure, computer  150  may comprise at least one processor unit  152 , memory  154 , signal detector  156 , a digital signal processor (DSP)  158 , and one or more user interfaces  160 . Computer  150  may include additional components without departing from the scope of the present disclosure. 
     The computer  150  may include at least one processor unit  152 , which may assist in the control and/or operation of PDF system  100 . The processor unit  152  may also be referred to as a central processing unit (CPU). Memory  154 , which may include both read-only memory (ROM) and random access memory (RAM), may provide instructions and/or data to the processor  504 . A portion of the memory  154  may also include non-volatile random access memory (NVRAM). The processor  152  typically performs logical and arithmetic operations based on program instructions stored within the memory  154 . The instructions in the memory  154  may be executable (by the processor unit  152 , for example) to implement the methods described herein. 
     The processor unit  152  may comprise or be a component of a processing system implemented with one or more processors. The one or more processors may be implemented with any combination of general-purpose microprocessors, microcontrollers, digital signal processors (DSPs), floating point gate arrays (FPGAs), programmable logic devices (PLDs), controllers, state machines, gated logic, discrete hardware components, dedicated hardware finite state machines, or any other suitable entities that can perform calculations or other manipulations of information. 
     The processor unit  152  may also include machine-readable media for storing software. Software shall be construed broadly to mean any type of instructions, whether referred to as software, firmware, middleware, microcode, hardware description language, or otherwise. Instructions may include code (e.g., in source code format, binary code format, executable code format, RS-274 instructions (G-code), numerical control (NC) programming language, and/or any other suitable format of code). The instructions, when executed by the one or more processors, cause the processing system to perform the various functions described herein. 
     The computer  150  may also include a signal detector  156  that may be used to detect and quantify any level of signals received by the computer  150  for use by the processing unit  152  and/or other components of the computer  150 . The signal detector  156  may detect such signals as energy beam source  103  power, deflector  105  position, build floor  111  height, amount of powder  117  remaining in depositor  101 , leveler  119  position, and other signals. The computer  150  may also include a DSP  158  for use in processing signals received by the computer  150 . The DSP  158  may be configured to generate instructions and/or packets of instructions for transmission to PDF system  100 . 
     The computer  150  may further comprise a user interface  160  in some aspects. The user interface  160  may comprise a keypad, a pointing device, and/or a display. The user interface  160  may include any element or component that conveys information to a user of the computer  150  and/or receives input from the user. 
     The various components of the computer  150  may be coupled together by a bus system  151 . The bus system  151  may include a data bus, for example, as well as a power bus, a control signal bus, and a status signal bus in addition to the data bus. Components of the computer  150  may be coupled together or accept or provide inputs to each other using some other mechanism. 
     Although a number of separate components are illustrated in  FIG. 1E , one or more of the components may be combined or commonly implemented. For example, the processor unit  152  may be used to implement not only the functionality described above with respect to the processor unit  152 , but also to implement the functionality described above with respect to the signal detector  156 , the DSP  158 , and/or the user interface  160 . Further, each of the components illustrated in  FIG. 1E  may be implemented using a plurality of separate elements. 
     By way of example, an element, or any portion of an element, or any combination of elements may be implemented as a “processing system” that includes one or more processors. Examples of processors include microprocessors, microcontrollers, graphics processing units (GPUs), central processing units (CPUs), application processors, digital signal processors (DSPs), reduced instruction set computing (RISC) processors, systems on a chip (SoC), baseband processors, field programmable gate arrays (FPGAs), programmable logic devices (PLDs), state machines, gated logic, discrete hardware circuits, and other suitable hardware configured to perform the various functionality described throughout this disclosure. One or more processors in the processing system may execute software. Software shall be construed broadly to mean instructions, instruction sets, code, code segments, program code, programs, subprograms, software components, applications, software applications, software packages, routines, subroutines, objects, executables, threads of execution, procedures, functions, etc., whether referred to as software, firmware, middleware, microcode, hardware description language, or otherwise. 
     In one or more aspects, the functions described may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium. Computer-readable media includes both computer storage media and communication media including any medium that facilitates transfer of a computer program from one place to another. A storage media may be any available media that can be accessed by a computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, compact disc (CD) ROM (CD-ROM) or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to carry or store desired program code in the form of instructions or data structures and that can be accessed by a computer. Also, any connection is properly termed a computer-readable medium. For example, if the software is transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of medium. Disk and disc, as used herein, includes CD, laser disc, optical disc, digital versatile disc (DVD), floppy disk and Blu-ray disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Thus, computer readable medium comprises a non-transitory computer readable medium (e.g., tangible media). 
     Accordingly, in one or more example embodiments, the functions described may be implemented in hardware, software, or any combination thereof. If implemented in software, the functions may be stored on or encoded as one or more instructions or code on a computer-readable medium. Computer-readable media includes computer storage media. Storage media may be any available media that can be accessed by a computer. By way of example, and not limitation, such computer-readable media can comprise a random-access memory (RAM), a read-only memory (ROM), an electrically erasable programmable ROM (EEPROM), optical disk storage, magnetic disk storage, other magnetic storage devices, combinations of the aforementioned types of computer-readable media, or any other medium that can be used to store computer executable code in the form of instructions or data structures that can be accessed by a computer. 
       FIG. 2  shows a perspective view illustrating an additively manufactured node-node joint. 
     In an embodiment, a tongue-and-groove structure is used to connect two or more nodes.  FIG. 2  illustrates a perspective view of an additively manufactured node-node joint  200 . More specifically, node-node joint sections  200   a  and  200   b  are shown joined together at gap  208 . In some embodiments, node-node joint  200  may further include standoff tabs  202   a - 202   c  arranged around the perimeter of node-node joint  200 . In an exemplary embodiment, gap  208  is a 0.25 mm gap (or a gap of another dimension) configured to enable proper spacing of nodes composed of dissimilar metals or other materials. This spacing may ensure that the two subcomponents being joined are not in physical contact so that galvanic corrosion can be avoided. The spacing insulates the nodes/subcomponents. In some embodiments, sealants, in addition to providing seals, may act as spacers as well. In other embodiments lacking corrosion concerns due to the application of coatings or other treatment methods, such as e-coat, on the nodes, the node-node joint sections  200   a  and  200   b  may be flush against each other such that no gap is present and not require sealants. Each of node-node joint sections  200   a  and  200   b  may include a side wall  210  in the interior of node-node joint  200 . 
     Node to node joint  200  may further include inlet port  204  to enable entry of an adhesive into the node-node joint  200  and vacuum port  206  for drawing a vacuum to facilitate the flow of adhesive within node-node joint  200 . In the embodiment shown, respective inlet and vacuum ports  204  and  206  are built within node  200   b  and designed to provide a flow of adhesive to assist in adjoining nodes  200   a  and  200   b  as described below. In other embodiments, adhesive may be directly deposited into the node-node joint  200  prior to curing to realize a structural connection between the two subcomponents. 
       FIG. 3  shows a cross-sectional view illustrating the node-node joint of  FIG. 2 . 
       FIG. 3  illustrates a cross-sectional view of the node-node joint  200  taken along plane A-A-A-A. In this view, side wall  210  of  FIG. 3  corresponds to side wall  210  of  FIG. 2 , and standoff tab  202   b  of  FIG. 3  corresponds to standoff tab  202   b  of  FIG. 2 . Shown on side wall  210  of  FIG. 2  is gap  208 . The tongue portion  302  of the node-node joint  300  is part of node  200 A, includes a first material represented by the diagonal lines of node  200 A, and is disposed along a generally peripheral region  310  of the node  200 A. In one embodiment, the tongue portion  302  extends all the way around the peripheral region  310  and is in effect a single protrusion disposed around the peripheral region  310 . The tongue portion  302  protrudes outward along the peripheral region  310  relative to node  200 B and around node  200 A, and the lateral extension of tongue portion  302  can be considered in this view as coming out of the figure. The groove portion  304  of the node-node joint  300  is part of node  200 B and is disposed along a generally peripheral region  312  of the node  200   b . The groove portion  304  may, but need not, be composed of the material of node  200   b , wherein the material is represented by the diagonal lines in node  200   b  that run in a direction opposite the diagonal lines of node  200   a . In one embodiment, the groove portion  304  extends all the way around the peripheral region  312  and is in effect a single indentation in the node  200   b  all the way around peripheral region  312 . The groove portion  302  is inset inward along the peripheral region  312  relative to node  300   a  and runs laterally around node  300   b  and can also be considered in this view as coming out of the figure. Tongue  302  and groove  304  may be arranged on respective nodes  200   a  and  200   b  such that when the two nodes are properly placed into contact, tongue  302  may align with groove  304  and may fit into groove  304  around the peripheral regions  310 ,  312 . 
     In an exemplary embodiment, groove  304  includes centering feature  308  which is a narrow region that widens the opening of groove  302  and assists in enabling tongue  302  to properly mate with groove  304  to thereby center the node-node joint  300 . In another exemplary embodiment, spill-off sealant reservoirs  326  are provided on each side of the tongue  302 , each reservoir  326  having sealant grooves  320  that may be used for the application of an appropriate sealant, e.g., to control the flow of an adhesive to be applied. 
     As shown relative to  FIGS. 2 and 3 , adhesive and vacuum ports  204  and  206  are respectively provided. In one embodiment, a sealant is first applied at the sealant grooves  320  of node  200   a . The two nodes  200   a  and  200   b  may then be aligned and fixed securely in place using standoff tabs  202   a - c  as alignment points. A vacuum may be applied at vacuum port  206  to ensure that the nodes are sealed. Once a complete seal has been obtained, an adhesive may be applied through inlet port  204 . In one embodiment, the internal structure of vacuum port  206  is similar to that of inlet port  204 . The adhesive-vacuum action causes the adhesive to seep into the space between the tongue  302  and the groove  304  and to flow in this space around the peripheral region  310 ,  312  until the adhesive has properly saturated the tongue grove connection around the peripheral region. 
     In an embodiment, the standoff tabs  220   a - c  may also be used to assist in preventing sealant pushback during the adhesive flow and curing process. Once the adhesive fills the gap between the tongue  302  and the groove  304  sections substantially completely, the adhesive may be allowed to cure. The vacuum pressure during the adhesive flow process may be monitored and may be indicative of a complete adhesive fill. On completion of the cure, the standoff tabs may in one embodiment be broken off. 
     Using this technique, nodes can be efficiently and durably combined. The use of AM in one embodiment creates the structure necessary for implementing the joining of the nodes such that additional processes beyond application of an adhesive and/or sealant, such as welding or the use of various external fastening mechanisms, are not necessary. 
     In another aspect of the disclosure, techniques for joining subcomponents of a larger additively manufactured component, such as an engine, transmission, gear case, etc., are disclosed. In the discussion that follows, the present disclosure will be illustrated in the context of an additively manufactured gear case within the transmission of a transport structure. It will be appreciated, however, that the teachings of the present disclosure are not so limited, and any number and types of additively manufactured components may be assembled using the principles describe herein. 
       FIG. 4  illustrates a perspective cross-section view of a node, in accordance with various aspects of the present disclosure. 
       FIG. 4  illustrates a cross-section view of a node  400 . Node  400  may be similarly configured as nodes  200   a ,  200   b  of  FIG. 2 . The node  400  may be a primary structure and/or a part of a primary structure configured to receive safety and operational loads of a vehicle. Examples of node  400  may include crash structure, chassis, a portion of a chassis, fuselage, occupant safety cell, a portion of an occupant safety cell, payload storage, and the like. While not shown in  FIG. 4 , node  400  may include one or more inlet ports and one or more vacuum ports. 
     Node  400  may include various sections  412   a ,  412   b ,  412   c ,  412   d ,  412   e ,  412   f ,  412   g ,  412   h ,  412   i ,  412   j , around a peripheral portion of node  400 , and collectively referred to herein as peripheral sections  412 . In some implementations, a peripheral portion of the node  400  may be divided into the peripheral sections  412  as shown in  FIG. 4 . Each of the peripheral sections  412  may include a cavity and be configured to receive various types of material including but not limited to adhesive material, conductive polymer. 
     In some implementations, a subset of the peripheral sections  412  may be configured to receive structural adhesive material  404  and another subset of the peripheral sections  412  may be configured to receive conductive material  406 . For example, as shown in  FIG. 4 , peripheral sections  412   a ,  412   c ,  412   d ,  412   f ,  412   h , and  412   i  receive structural adhesive material  404 , and peripheral sections  412   b ,  412   e ,  412   g ,  412   j  receive conductive material  406 . The structural adhesive material  404  and conductive material  406  may be injected into the peripheral sections  412  during an assembly process using the node  400  and/or assembly of the node  400 . In some implementations conductive material  406  may be a conductive polymer. 
     The peripheral portion of the node  400  may include one or more joints, such as joints  402   a ,  402   b ,  402   c ,  402   d ,  402   e ,  402   f ,  402   g , collectively referred to herein as multifunction joints  402 . In some implementations, one or more of the multifunction joints  402  may include a cavity (not shown separately), where the cavity may be adapted to hold one or more connectors (not shown separately). In some implementations, as described herein a “connector” may be an interconnect, coupler, or other device for coupling a component (e.g., node  400 ) with another component (e.g., another node). In some implementations, the connectors may include a groove, a cup, a channel, a furrow, and or other indentation. In some connectors may include a tongue, a cone, an extrusion, and/or other extensions. 
     Node  400  may be configured with cavity  414 , as shown in  FIG. 4 . The cavity  414  may be configured to receive energy storage modules (not shown in  FIG. 4 ). The node  400  may be co-printed with an electrical conductive path, such as a bus bar. The electrical conductive path may be configured to connect the energy storage module received in the node with other electrical components of a vehicle. Additional details of the electrical conductive path and/or bus bar are described herein with respect to  FIGS. 5-9 . 
     Turning now to  FIG. 5A , there is shown a perspective view  500   a  of a node with co-printed electrical conductive path (e.g., bus bar), in accordance with various aspects of the present disclosure. For the purpose of illustrating a clear example, only a portion of the node  502  is illustrated in  FIG. 5A . In  FIG. 5A , the node  502  may be co-printed with bus bar  504 . The bus bar  504  may be an electrical conductive path that connects an energy storage module (not shown in  FIG. 5A ) with the other electrical components of a vehicle. In some implementations, the bus bar  504  may include one or more electrical connections and the like. 
     In some implementations, the bus bar  504  may be co-printed with the node  502 , by co-printing supports  308  as shown in  FIG. 5A . Each of the supports  508  is co-printed to connect a portion of the bus bar  504  with the portion of the node  502 . The supports  508  may be removed during an assembly process of assembling the node  502  with other nodes, components, structures, and the like of the vehicle. For example, the supports  508  may be removed by machining away the supports  508 . The supports  508  may, in certain embodiments, be co-printed with printing parameters that make it structurally weaker than the bus bar  504  and/or node  502 . In other embodiments, the supports  508  may be removed using a chemical process. 
     The node  502  includes a cavity  510  configured to receive an energy storage module (not shown in  FIG. 5A ). The bus bar  504  may be electrically connected to the energy storage module. Additional details of the bus bar electrically connected to the energy storage modules in described herein with respect to  FIGS. 6-9 . In some implementations, the supports  508  may be removed and/or machined when the cavity  510  receives the energy storage module and/or when the bus bar  504  is electrically connected with the energy storage modules. 
     The bus bar  504  may be electrically insulated from other components of the node  502  and/or other components of the vehicle. For example, an injectable insulator may be extruded and/or otherwise applied on a surface of the bus bar  504  and/or the energy storage device. In some implementations, an electro coating of metallic substrates with dielectric solution may be applied to the bus bar  504  and/or the energy storage device. In some implementations, a curable insulation may be extruded on and/or otherwise applied to metallic substrates and cured in-place. For example, an ultraviolet (UV) cured insulating material may be applied to a metallic substrate (e.g., metallic substrate of the bus bar  504 , metallic substrate of the energy storage module, and the like) and cured in-place with UV light. In some implementations, thermoplastics may be applied, printed and/or co-printed onto metallic substrates. 
     The bus bar  504  may include an indentation and/or an extension that is configured to connect with another bus bar. For example, as shown in  FIG. 5A , the bus bar  504  includes tongue  506 . The tongue  506  may be configured to extend into an indentation, such as a groove, of another bus bar. As shown in  FIG. 5A , the tongue  506  is included at one end of the bus bar  504 . While not shown in  FIG. 5A , in some implementations, at the other end of the bus bar  504  may include an indentation, such as a groove, a cup, a channel, a furrow, and or other indentation. In some implementations, the other end of the bus bar  504  may include another extension, such as a tongue, a cone, an extrusion, and/or other extensions. 
     Turning now to  FIG. 5B , there is shown another example of a bus bar  512  co-printed with the node  522 . Bus bars  512  and node  522  may be configured similarly to bus bar  504  and node  502 . Supports  514  may be co-printed similarly as described in  FIG. 5A , and may be removed and/or machined away in a similar manner the remove and/or machining away of supports  508  as described above with respect to  FIG. 5A . 
     Similar to node  502 , node  522  includes a cavity  520  that may be configured to receive an energy storage module and/or a portion of another energy storage module (e.g., a portion of the energy storage module received in node  502 ). The bus bar  512  may be electrically connected to the energy storage module received in the node  522 . The bus bar  512  may be include an indentation, such as, a cup, a channel, a furrow, and or other indentation. For example, the bus bar  512  may include a groove  518  at one end of the bus bar  512 . In some implementations, the bus bar  512  may include another indentation, such as, a cup, a channel, a furrow, and or other indentations at the other end of the bus bar  512 . For example, the bus bar  512  may include a groove  516  at one end of the bus bar  512 . In some implementations, the bus bar  512  may include an extension, such as a tongue, a cone, an extrusion, and/or other extensions. 
     The bus bar  504  and the bus bar  512  may connect with each other via the tongue  506  of the bus bar  504  and the groove  516  of bus bar  512 . In some implementations, the tongue  506  and the groove  516  may be configured to mate with each other. For example the groove  516  may be configured to receive the tongue  506 . An injectable conductor may be inserted and/or injected between the extensions (e.g., extension  506 ) and the indentations (e.g., groove  516 ). Additional details of the injecting a conductor is described herein with respect to  FIG. 6 . 
     Turning now to  FIG. 6 , there is shown a bus bar  602  with a groove  606  and a bus bar  604  with a tongue  608 . The bus bar  602  and the bus bar  604  are connected with each other. The bus bars  602  and  604  may be connected with energy storage module(s). As shown in  FIG. 6 , the tongue  608  may be configured to be mated with the groove  604 . Injectable conductor  610  may be provided and/or injected into the groove  606 . The injectable conductor  610  may allow for electrical conductive path to continue between the bus bars  602  and  604  and between the energy storage modules of to which the bus bars  602  and  604  are electrically connected. 
     In some implementations, two bus bars (e.g., bus bars  602  and  604 ) may be connected with each other via fastening components, such as a screw fasteners, rivets, ultrasonic welding, fusion welding, and the like. In some implementations, two bus bars may be connected with other via mechanical fasteners (e.g., self-taping screws, flow drills, and the like) that expose a conductor to allow the electrical connection to continue between the two bus bars. 
     In some implementations, curable conductive materials can be used for electrical connections between the bus bars and the energy storage modules. The curable conductive material may be cured during a heat cycle. In some embodiments, the curable conductive material may be cured either before, during, or after the curing of the structural adhesive between node-based subcomponents that incorporate the bus bars as described herein. 
     Turning now to  FIG. 7 , there is shown a cross-sectional view of a co-printed bus bar connected with an energy storage module in a node, in accordance with various aspects of the present disclosure. 
     In  FIG. 7 , node  702  includes an energy storage module  710 , and a bus bar  706  is co-printed with node  702  with the supports  708 . In this embodiment, the node  702  may be the primary structure of the vehicle (e.g., chassis, subframes, frames, etc.). The supports  708  may be removed and/or machined away after connection of the bus bar  706  with the energy storage module  710 . The bus bar  706  is electrically connected with energy storage module  710 . As described above, the bus bar  706  may be electrically insulated from other components. As shown in  FIG. 7 , insulator  704  may be applied to a surface of bus bar  706 . The insulator  704  may be an injectable insulator  704 . In  FIG. 7 , while the insulator  704  is applied between bus bar  706  and the energy storage module  710 . However, the insulator  704  does not interfere with the electrical connections between bus bar  706  and energy storage module  710 . 
     Turning now to  FIG. 8 , there is shown a perspective view of a bus bar connected with energy storage modules, in accordance with various aspects of the present disclosure. 
     In  FIG. 8 , bus bar  802  is electrically connected with energy storage modules  804   a  and  804   b . While the bus bar  802  is depicted as a single bus bar in  FIG. 8 , in some implementations, the bus bar  802  may be formed by connecting multiple bus bars as described above with respect to  FIGS. 5-6 . 
     Each of the energy storage modules  804   a  and  804   b  may include one or more energy storage cells, such as energy storage cells  808 . In some implementations, each of the energy storage cells  808  may be electrically connected with other energy storage cells  808  of an energy storage module. To provide electric insulation between the energy storage modules and other components of the node, and/or the vehicle, each energy storage module  804   a , and  804   b  may be insulated, for example, by dielectric insulation. 
     The bus bar  802  may be electrically connected to the energy storage modules  804   a ,  804   b  via the electrical connections  810 . Examples of electrical connections  810  may comprise various electrical conductive paths including, but are not limited, to electrical links, wires, and/or other electrical conductive materials. The bus bar  802  may be co-printed with a node similar to the techniques described above with respect to  FIGS. 5-7 . The energy storage modules  804   a ,  804   b  may either be included in the node, co-printed with the bus bar  802 . 
     Turning now to  FIG. 9 , there is shown bus bars connected with energy storage modules and other components of a vehicle, in accordance with various aspects of the present disclosure. 
     In  FIG. 9 , there is shown a motor  902  (e.g., electric motor) electrically connected to an inverter  906  via electrical link  904 . In some implementations, the electrical link  904  may be a direct current (DC) link. The inverter  906  maybe electrically connected to a contactor  910  via electrical link  908 . The electrical link  908  may be a DC link. 
     The bus bars  912  are electrically connected to the contactor  910  via electrical links  916 . The bus bars  912  are electrically connected to the energy storage modules  914 . Therefore, the bus bars  912  connect the energy storage modules  914  with the other components shown in  FIG. 9 . For example by being electrically connected with the energy storage modules  914 , the bus bars  912  connect the energy storage modules  914  to the motor  902  via the electrical links  916 , contactor  910 , DC link  908 , inverter  906 , and DC link  904 . 
     While not shown in  FIG. 9 , the bus bars  912  and energy storage modules  914  may be included within different nodes as described herein. The bus bars  912  may be co-printed with nodes. 
     The techniques of co-printing of the bus bars with the nodes and joining of nodes and/or bus bars as described herein allow for bus bars to be manufactured for any shape of a node. The bus bars described herein may be manufactured using materials with low density and high stiffness (e.g., light alloys) to achieve a low or the lowest possible mass structure. In some embodiments, the structural portions, i.e., the nodes, and the bus bars may be printed with the same material. Parameters may be adjusted during the 3D printing process to effect electrical properties (e.g., increased resistivity, conductivity, etc.). In alternate embodiments, a multi-material printing process may be used wherein the structural portions, i.e., the nodes, may be printed with aluminum or alloys thereof, while the bus bars may be printed with copper. 
     The bus bars and the nodes may be manufactured using the same base material, and by co-printing the bus bars and the nodes, the mass of the structure and/or the total mass of the vehicle may be optimized. Furthermore, co-printing the bus bars and the nodes allows for further design optimization as it allows for complex structures to be realized. 
     Turning now to  FIG. 10 , there is shown a flow diagram  1000  illustrating an exemplary method for co-printing conductive paths (e.g., electrical conductive paths, bus bars, and the like) for printed structural energy storage modules in accordance with various aspects of the present disclosure. It should be understood that the steps identified in  FIG. 10  are exemplary in nature, and a different order or sequence of steps, and additional or alternative steps, may be undertaken as contemplated in this disclosure to arrive at a similar result. 
     At step  1002 , a first component (e.g., nodes  200   a ,  200   b ,  400 ,  502 ,  522 ) may be additively manufactured (e.g., using one or more AM and/or three-dimensionally (3D) print processes described herein), such that the first component is configured to be a primary structure of the vehicle. The first component may be co-printed with a first electrical conductive path (e.g.,  504 ,  512 ). The first electrical conductive path may be configured to be connected to a second electrical conductive path (e.g.,  512 ,  504 ) of a second component (e.g., nodes  200   a ,  200   b ,  400 ,  502 ,  522 ) of the vehicle. 
     At optional step  1004 , an electrical insulator may be injected between the first conductive path and the first component. 
     In some implementations, the first electrical conductive path is configured to be connected to the second electrical conductive path through an injectable conductor (e.g., injectable conductor  610 ). In some implementations, the first component comprises at least a tongue structure (e.g., tongue portion  302 ) configured to mate with a corresponding groove structure (e.g., grooves  304 ,  320 ) of the second component. The first electrical conductive path (e.g.,  504 ,  512 ) may pass through a portion of the tongue structure of the first component, or a groove structure configured to mate with a corresponding tongue structure of the second component. The second electrical conductive path (e.g.,  512 ,  504 ) may pass through a portion of the tongue structure of the second component. 
     In some implementations, the first component is co-printed with a first set of supports (e.g.,  508 ,  514 ), each support of the first set of supports is connected to a portion of the first electrical conductive path. In some implementations, the first component is configured to receive at least a portion of a first energy storage module (e.g.,  710 ). In some implementations, the first electrical conductive path (e.g.,  802 ) is configured to be connected (e.g., connections  810 ) to the first energy storage module (e.g.,  804   a ,  804   b ). In some implementations, the first electrical conductive path comprises a bus bar. 
     The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these exemplary embodiments presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be applied to other techniques for printing and joining nodes and subcomponents. Thus, the claims are not intended to be limited to the exemplary embodiments presented throughout the disclosure, but are to be accorded the full scope consistent with the language claims. All structural and functional equivalents to the elements of the exemplary embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. § 112(f), or analogous law in applicable jurisdictions, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”