A battery module includes a module terminal, electrochemical cells and a bus bar that electrically connects at least a subset of the cells to the module terminal. The bus bar includes an electrically conductive substrate and an insulation layer disposed between the substrates and ends of the cells. The substrate includes primary connection through holes, each primary connection through hole having a second diameter and being aligned with the first end of a unique one of the cells. The insulation layer includes secondary connection through holes. Each secondary connection through hole has a third diameter and is concentric with a corresponding one of the primary through holes. The third diameter is less than the second diameter, and an electrical connector extends between the substrate and the cell terminal and provides an electrical connection between the substrate and the cell terminal.

A battery module includes a module terminal, electrochemical cells and a bus bar that electrically connects at least a subset of the cells to the module terminal. The bus bar includes an electrically conductive substrate and an insulation layer disposed between the substrates and ends of the cells. The substrate includes primary connection through holes, each primary connection through hole having a second diameter and being aligned with the first end of a unique one of the cells. The insulation layer includes secondary connection through holes. Each secondary connection through hole has a third diameter and is concentric with a corresponding one of the primary through holes. The third diameter is less than the second diameter, and an electrical connector extends between the substrate and the cell terminal and provides an electrical connection between the substrate and the cell terminal.

Method of producing a low interfacial contact resistance material for use in batteries or connectors and a low interfacial contact resistance material for use in batteries or connectors produced thereby.

Method of producing a low interfacial contact resistance material for use in batteries or connectors and a low interfacial contact resistance material for use in batteries or connectors produced thereby.

An apparatus includes a component having an edge feature that has a radius of curvature. The apparatus includes an underlayer arranged over the edge feature and configured to increase the radius of curvature of the edge feature. The apparatus includes a powder coating arranged over the component and over the underlayer to form a continuous layer. The underlayer is configured to remain under the powder coating. The underlayer helps the powder coating achieve a more uniform thickness over the edge feature. The apparatus is formed by applying an underlayer to a first region of the component to form an underlaid component. The first region includes the edge feature. A powder coating is applied to the underlaid component. A masking layer may be applied to a region other than the first region, and after powder coating, the masking may be removed to expose a surface of the component.

Provided is a busbar capable of keeping a joint strength high at a joint between dissimilar metals. The busbar (2) joins terminals of a plurality of battery cells, the terminals each including a dissimilar metal. The busbar includes: a copper portion (2e) to be connected to a first terminal (in) of a first battery; an aluminum portion (2f) to be connected to a second terminal (1p) of a second battery; and a joint (2x) including the copper portion bonded to the aluminum portion. The aluminum portion is placed so as not to overlap the bonding region between the first terminal and the copper portion, and has arms (2f1) extending in a direction from the second terminal to the first terminal. The joint includes the copper portion bonded to the arms, and the arms have a width such that a proximal end portion is wider than a distal end portion of the arms.

Provided is a busbar capable of keeping a joint strength high at a joint between dissimilar metals. The busbar (2) joins terminals of a plurality of battery cells, the terminals each including a dissimilar metal. The busbar includes: a copper portion (2e) to be connected to a first terminal (in) of a first battery; an aluminum portion (2f) to be connected to a second terminal (1p) of a second battery; and a joint (2x) including the copper portion bonded to the aluminum portion. The aluminum portion is placed so as not to overlap the bonding region between the first terminal and the copper portion, and has arms (2f1) extending in a direction from the second terminal to the first terminal. The joint includes the copper portion bonded to the arms, and the arms have a width such that a proximal end portion is wider than a distal end portion of the arms.

The present invention relates to a multilayer divergence type busbar that is easy to manufacture and has various shapes and a method of manufacturing the same. The divergence type busbar is configured such that at least two conductive layers are stacked and some of the conductive layers are divided and diverged at a divergence point.

The present invention relates to a multilayer divergence type busbar that is easy to manufacture and has various shapes and a method of manufacturing the same. The divergence type busbar is configured such that at least two conductive layers are stacked and some of the conductive layers are divided and diverged at a divergence point.

An interconnection for a battery comprising a plurality of cells having connection tabs. The interconnection comprises a first electrically insulating substrate, a heat sink, a plurality of tab-receiving regions, a plurality of aperture and electrically insulating material. The first electrically insulating substrate has a first face on a first side of the interconnection and a second face. The heat sink is thermally connected to the second face of the first substrate. The plurality of tab-receiving regions comprise electrically conducting material on the first side of the interconnection for receiving connection tabs of the cells. The plurality of apertures extend through the interconnection, wherein the apertures are arranged to allow connection tabs of the cells to extend from a second side of the interconnection, through the apertures, and to the first side of the interconnection for establishing contact with the tab-receiving regions on the first side of the interconnection. The electrically insulating material is arranged to insulate the apertures from the heat sink, such that connection tabs extending through the apertures are electrically insulated from the heat sink.