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 module of the present disclosure may include, a cell assembly including at least one battery cell, a busbar assembly including a terminal busbar electrically connected to an electrode lead of the cell assembly, and a busbar frame covering the cell assembly on at least one side, and an insulating frame covering the busbar assembly from the outside, and further including a nut which is set to a floatable size in a nut insertion chamber adjacent to a terminal busbar and provided with a space inside the insulating frame, and is mounted in the nut insertion chamber.

A battery module of the present disclosure may include, a cell assembly including at least one battery cell, a busbar assembly including a terminal busbar electrically connected to an electrode lead of the cell assembly, and a busbar frame covering the cell assembly on at least one side, and an insulating frame covering the busbar assembly from the outside, and further including a nut which is set to a floatable size in a nut insertion chamber adjacent to a terminal busbar and provided with a space inside the insulating frame, and is mounted in the nut insertion chamber.

A method for forming a connection between a first battery cell (1) and a second battery cell (2), wherein, in a first method step, an adhesive (3) comprising at least one first component (31) and at least one second component (32) is applied to the first battery cell (1), wherein a first proportion (41) of the at least one first component (31) and/or a second proportion (42) of the at least one second component (32) is changed during the application of the adhesive (3) over the first battery cell (1), wherein, in a second method step, the first battery cell (1) is connected to the second battery cell (2) in such a way that an inhomogeneous material bond is formed between the first battery cells (1) and the second battery cell (2).

A method for forming a connection between a first battery cell (1) and a second battery cell (2), wherein, in a first method step, an adhesive (3) comprising at least one first component (31) and at least one second component (32) is applied to the first battery cell (1), wherein a first proportion (41) of the at least one first component (31) and/or a second proportion (42) of the at least one second component (32) is changed during the application of the adhesive (3) over the first battery cell (1), wherein, in a second method step, the first battery cell (1) is connected to the second battery cell (2) in such a way that an inhomogeneous material bond is formed between the first battery cells (1) and the second battery cell (2).

The invention generally provides a busbar for use in mechanically and electrically connecting components in a device. The busbar includes a plurality of conductors arranged to provide two opposed end portions and an intermediate portion, wherein each of the conductors has a plurality of intermediate extents that traverse the intermediate portion. The intermediate portion including: (A) an unfused segment where no intermediate extents of the conductors are fused together to form a single consolidated conductor, and (B) a fused segment that includes (i) a partial solidification zone where a majority of the intermediate extents of the conductors are fused together to form a partially solidified region that provides a single consolidated conductor, (ii) a full solidification zone where all of intermediate extents of the conductors are fused together to form a fully solidified region that provides a single consolidated conductor, and (iii) an unsolidified region where all of the intermediate extents of the conductors are not fused together.

A fusing system for a brick of lithium ion battery in a battery module is provided where the fusing system has a combination of low-voltage fuses and a high-voltage fuse. The low-voltage fuse can have one or more fusing elements in a springy spiral configuration or a straight configuration with the fuse element encapsulated.

Examples of the present disclosure describe a flexible connector mechanism that may be used to form an electrical connection and/or a communication link between one or more devices. The flexible connector mechanism may comprise one or more interface components that may each comprise one or more contact portions. The interface components may be configured to be selectively coupled to one or more corresponding components of a coupleable object. The flexible connector mechanism may also comprise a flexible portion that enables the interface components to be manipulated along one or more planes or axes. The flexibility of the flexible portion may enable the interface components of the flexible connector mechanism to be adjusted into, and maintained in, an optimal (or operable) position when coupled to a coupleable object in motion.

Examples of the present disclosure describe a flexible connector mechanism that may be used to form an electrical connection and/or a communication link between one or more devices. The flexible connector mechanism may comprise one or more interface components that may each comprise one or more contact portions. The interface components may be configured to be selectively coupled to one or more corresponding components of a coupleable object. The flexible connector mechanism may also comprise a flexible portion that enables the interface components to be manipulated along one or more planes or axes. The flexibility of the flexible portion may enable the interface components of the flexible connector mechanism to be adjusted into, and maintained in, an optimal (or operable) position when coupled to a coupleable object in motion.