The busbar has a planar portion and multiple blisters that project from it. The blisters have a beam-like structure and provide structural rigidity to the busbar. When the ends of the blisters are connected to the terminals of the cells in the battery, the battery assembly is provided with structural strength. The busbars may be arranged side-by-side or in layers. When in layers, the blisters of the upper busbars project through holes in the lower busbars. Busbar assemblies may include insulating spacers, insulating layers, or venting features. By using the busbar as a structural member, the required strength and weight of the remaining components of the battery pack are reduced.

A bus bar holder for a battery module is provided. The bus bar holder includes: a body having a plurality of bus bar disposal area portions; and a hinge portion between the plurality of bus bar disposal area portions and configured to enable stacking of the plurality of bus bar disposal area portions.

A bus bar holder for a battery module is provided. The bus bar holder includes: a body having a plurality of bus bar disposal area portions; and a hinge portion between the plurality of bus bar disposal area portions and configured to enable stacking of the plurality of bus bar disposal area portions.

A battery module comprising a plurality of battery cells having two opposite ends, a first busbar assembly comprising at least a first busbar coupled with a first busbar frame, and a second busbar assembly comprising at least a second busbar coupled with a second busbar frame configured to electrically couple the battery cells, and a main frame having side walls forming a housing and a middle wall inside the housing dividing an inner space of the housing in a vertical direction to a first and a second section, wherein the middle wall comprises a plurality of holes for receiving the battery cells such that one end of battery cell is in the first section and another end is in the second section, and wherein the middle wall further comprises a plurality fastening members for fastening the first busbar assembly to the main frame in the first section and the second busbar assembly to the main frame in the second section such that the battery cells are arranged between the first and the second busbar assemblies which couple the battery cells to the battery module.

A battery module comprising a plurality of battery cells having two opposite ends, a first busbar assembly comprising at least a first busbar coupled with a first busbar frame, and a second busbar assembly comprising at least a second busbar coupled with a second busbar frame configured to electrically couple the battery cells, and a main frame having side walls forming a housing and a middle wall inside the housing dividing an inner space of the housing in a vertical direction to a first and a second section, wherein the middle wall comprises a plurality of holes for receiving the battery cells such that one end of battery cell is in the first section and another end is in the second section, and wherein the middle wall further comprises a plurality fastening members for fastening the first busbar assembly to the main frame in the first section and the second busbar assembly to the main frame in the second section such that the battery cells are arranged between the first and the second busbar assemblies which couple the battery cells to the battery module.

A battery pack includes a plurality of battery cells; and a bus bar electrically connected to the plurality of battery cells, wherein the bus bar includes a single-layer portion and a multi-layer portion, the multilayer portion having different numbers of stacks in the thickness direction, the single-layer portion includes a first material layer, and the multi-layer portion includes a first material layer continuously connected from the first material layer of the single-layer portion and a second material layer on at least one of a front surface or a rear surface of the first material layer.

A battery pack includes a plurality of battery cells; and a bus bar electrically connected to the plurality of battery cells, wherein the bus bar includes a single-layer portion and a multi-layer portion, the multilayer portion having different numbers of stacks in the thickness direction, the single-layer portion includes a first material layer, and the multi-layer portion includes a first material layer continuously connected from the first material layer of the single-layer portion and a second material layer on at least one of a front surface or a rear surface of the first material layer.

A battery pack includes: a plurality of battery cells arranged into rows adjacent to each other, adjacent rows of battery cells being alternately shifted to front positions or rear positions in a row direction; busbars arranged to form a parallel group of battery cells by connecting a group of battery cells to each other in parallel, and connecting adjacent parallel groups to each other in series, the busbars including a body portion extending in a zigzag shape in a column direction and a first and second branch portion extending in the row direction from the body portion toward different parallel groups; and expansion pieces protruding from the body portion of the busbar to external positions outside the plurality of battery cells in the row direction or the column direction.

A battery module includes a housing having an internal space; a cell stack accommodated in the internal space and including a plurality of battery cells and a plurality of heat blocking members stacked therein; a busbar assembly including a busbar frame opposing at least one side surface of the cell stack, and a plurality of busbars coupled to the busbar frame and electrically connected to the plurality of battery cells, wherein at least one of the plurality of heat blocking members includes an extension portion inserted into the busbar frame and preventing an electrical short circuit between the plurality of busbars.

A battery module includes a housing having an internal space; a cell stack accommodated in the internal space and including a plurality of battery cells and a plurality of heat blocking members stacked therein; a busbar assembly including a busbar frame opposing at least one side surface of the cell stack, and a plurality of busbars coupled to the busbar frame and electrically connected to the plurality of battery cells, wherein at least one of the plurality of heat blocking members includes an extension portion inserted into the busbar frame and preventing an electrical short circuit between the plurality of busbars.