An ultrasonic bonding method for electrical contacting a plurality of battery cells of a battery block. A first connection point is produced in that a bonding tool is heated directly, and a first connection contact surface of a first battery cell and/or a connection conductor is/are heated locally and indirectly by a laser beam directed toward the bonding tool. The connection conductor is pressed against the first connection contact surface of the first battery cell. The bonding tool is excited to vibrate ultrasonically, the ultrasonic vibrations being transferred from the bonding tool to the connection conductor. A second connection point is produced in that the connection conductor is pressed against a second connection contact surface of a second battery cell of the battery block or a common connection contact of the battery block by the bonding tool and excited to vibrate ultrasonically.

An ultrasonic bonding method for electrical contacting a plurality of battery cells of a battery block. A first connection point is produced in that a bonding tool is heated directly, and a first connection contact surface of a first battery cell and/or a connection conductor is/are heated locally and indirectly by a laser beam directed toward the bonding tool. The connection conductor is pressed against the first connection contact surface of the first battery cell. The bonding tool is excited to vibrate ultrasonically, the ultrasonic vibrations being transferred from the bonding tool to the connection conductor. A second connection point is produced in that the connection conductor is pressed against a second connection contact surface of a second battery cell of the battery block or a common connection contact of the battery block by the bonding tool and excited to vibrate ultrasonically.

A battery cell fixture (112) is disclosed, wherein a plurality of battery cells (114) are supportable by the battery cell fixture (112) in a predefined relative position to each other. The battery cell fixture (112) comprises: two electrical connection portions (116), at least two busbars (118) configured for, in case the battery cells (114) are supported in the battery cell fixture (112), electrically contacting at least one of the battery cell's electrodes (120) such that a current is transmittable via the busbars (118) from the electrodes (120) to the electrical connection portions (116), and at least one plastic frame element (122) generated by at least partially overmolding at least one of the at least two busbars (118).

Further, a method of manufacturing a battery cell fixture (112) is disclosed. Furthermore, a battery module (110) and a method of manufacturing a battery module (110) are disclosed.

A current collector assembly (CCA) with an insulative structure is provided. A battery system can include the current collector assembly formed from the insulative structure. The current collector assembly can include a conductor layer at least partially encapsulated by the insulative structure. The current collector assembly can include a conductor array cut from the conductor layer. A first portion of the conductor array can contact a positive terminal of a first group of battery cells, and a second portion of the conductor array can contact a negative terminal of a second group of battery cells. The rib can be formed from the insulative structure of the current collector assembly.

A current collector assembly (CCA) with an insulative structure is provided. A battery system can include the current collector assembly formed from the insulative structure. The current collector assembly can include a conductor layer at least partially encapsulated by the insulative structure. The current collector assembly can include a conductor array cut from the conductor layer. A first portion of the conductor array can contact a positive terminal of a first group of battery cells, and a second portion of the conductor array can contact a negative terminal of a second group of battery cells. The rib can be formed from the insulative structure of the current collector assembly.

A battery pack assembly includes an enclosure assembly that provides an interior area. Battery cells are within the interior area. The battery cells each include at least one tab terminal that projects outward from the array axis. A frame provides at least one slot that receives a portion of the at least one tab terminal. At least one busbar is secured to the frame. A busbar shield is disposed between at least one cell and at least one busbar within a battery pack.

A battery pack assembly includes an enclosure assembly that provides an interior area. Battery cells are within the interior area. The battery cells each include at least one tab terminal that projects outward from the array axis. A frame provides at least one slot that receives a portion of the at least one tab terminal. At least one busbar is secured to the frame. A busbar shield is disposed between at least one cell and at least one busbar within a battery pack.

A bus bar includes a wiring pathway made from a conductive material and having bent portions bending at at least two sites of the wiring pathway. The wiring pathway includes members consecutively arranged to form a plate shape. At least two of the members have different characteristics. The members adjacent to each other are connected to each other by laser joining.

A bus bar includes a wiring pathway made from a conductive material and having bent portions bending at at least two sites of the wiring pathway. The wiring pathway includes members consecutively arranged to form a plate shape. At least two of the members have different characteristics. The members adjacent to each other are connected to each other by laser joining.

A busbar module includes: a busbar including an upper plate and a lower plate overlapping with the upper plate; an electrode lead positioned between the upper plate and the lower plate; and a connecting part disposed between the upper plate and the electrode lead to electrically connect the upper plate and the electrode lead, wherein a through hole is formed in the lower plate, and the connecting part is disposed at a position corresponding to the through hole.