A battery module having first and second cylindrical battery cells is provided. The module includes a laminated busbar assembly having a bottom isolation layer, a first busbar layer, an intermediate isolation layer, and a second busbar layer. The bottom isolation layer has a first aperture that receives the positive electrode of the first battery cell therethrough and exposes a portion of the negative electrode of the first battery cell. The first busbar layer has a first aperture that receives the positive electrode of the first battery cell therethrough. A portion of the first busbar layer electrically contacts the negative electrode of the first battery cell. The intermediate isolation layer has a first aperture that receives the positive electrode of the first battery cell therethrough. The second busbar layer electrically contacts the positive electrode of the first battery cell.

A battery module having first and second cylindrical battery cells is provided. The module includes a laminated busbar assembly having a bottom isolation layer, a first busbar layer, an intermediate isolation layer, and a second busbar layer. The bottom isolation layer has a first aperture that receives the positive electrode of the first battery cell therethrough and exposes a portion of the negative electrode of the first battery cell. The first busbar layer has a first aperture that receives the positive electrode of the first battery cell therethrough. A portion of the first busbar layer electrically contacts the negative electrode of the first battery cell. The intermediate isolation layer has a first aperture that receives the positive electrode of the first battery cell therethrough. The second busbar layer electrically contacts the positive electrode of the first battery cell.

A bus bar for use in conducting an alternating current may comprise multiple substantially parallel ribs and an electrically conductive attachment feature. Each rib may include a first and second end. Each rib may be provided for conducting a substantially equal portion of the current. The ribs may be spaced apart to provide gaps therebetween for airflow through the gaps. The electrically conductive attachment feature may connect the first ends of the plurality of ribs, and may be provided for attaching the plurality of ribs to an electrical component. A method for manufacturing a bus bar for use in conducting an alternating current may comprise attaching a plurality of electrically conductive strips to form a bus bar having a plurality of ribs, each rib having a first and second end, the ribs spaced apart to provide gaps therebetween for airflow through the gaps, the first ends of the plurality of ribs connected together.

A battery module for use with a controller includes a printed circuit board assembly (PCBA) mounted to a plurality of battery cells. The PCBA includes a substrate, a radio frequency (RF) communications circuit, a cell sensing circuit, and a conductive interconnecting member. The cell sensing circuit is operable for measuring a respective cell voltage of each of the battery cells. The conductive interconnect member forms an electrical connection between the battery cells. The RF communications circuit is in wireless communication with the controller and is operable for wirelessly transmitting the measured cell voltages to the controller. A battery system includes a master battery controller and the battery pack. A vehicle includes an electric machine operable for generating output torque for propelling the vehicle, as well as the battery system noted above.

The disclosure relates to microbattery devices and assemblies. In an embodiment, a device includes a plurality of microbatteries, a first flexible encapsulation film, and a second flexible encapsulation film. Each of the microbatteries includes a first contact terminal and a second contact terminal spaced apart from one another. The first flexible encapsulation film includes a first conductive layer electrically coupled to the first contact terminal of each of the microbatteries, and a first insulating layer on the first conductive layer. The second flexible encapsulation film includes a second conductive layer electrically coupled to the second contact terminal of each of the microbatteries, and a second insulating layer on the second conductive layer.

Provided are multilayered flexible battery interconnects for interconnecting batteries in battery packs and methods of fabricating thereof. A multilayered flexible battery interconnect comprises insulating layers and two conductive layers, stacked together and positioned between the insulating layers. One conductive layer is thicker than the other. The thinner conductive layer comprises flexible tabs for connecting to batteries and, in some examples, comprises voltage sense traces. The smaller thickness of these flexible tabs ensures welding quality and allows using less energy during welding. The battery cell contacts, to which these flexible tabs are welded, can be significantly thicker. Furthermore, the smaller thickness enables fusible link integration into flexible tabs. At the same time, the two conductive layers collectively conduct current within the interconnect, with the thicker layer enhancing the overall current-carrying capacity. The two conductive layers can be welded together to ensure electric connections and mechanical support.

Provided are multilayered flexible battery interconnects for interconnecting batteries in battery packs and methods of fabricating thereof. A multilayered flexible battery interconnect comprises insulating layers and two conductive layers, stacked together and positioned between the insulating layers. One conductive layer is thicker than the other. The thinner conductive layer comprises flexible tabs for connecting to batteries and, in some examples, comprises voltage sense traces. The smaller thickness of these flexible tabs ensures welding quality and allows using less energy during welding. The battery cell contacts, to which these flexible tabs are welded, can be significantly thicker. Furthermore, the smaller thickness enables fusible link integration into flexible tabs. At the same time, the two conductive layers collectively conduct current within the interconnect, with the thicker layer enhancing the overall current-carrying capacity. The two conductive layers can be welded together to ensure electric connections and mechanical support.

A cell connector for making electrically conductive contact with a plurality of battery cell terminals comprises a plurality of sections positioned next to each other including a plurality of first sections composed of an electrically conductive metal material, and at least one second section composed of an electrically insulating plastic. The at least one second section is positioned between a respective two of the plurality of first sections. The present disclosure further relates to a method for producing a cell connector, in which the at least one second section is connected to the at least two first sections by means of a nano-moulding method. The present disclosure furthermore relates to a battery module having a plurality of battery cells with terminals connected by at least one cell connector.

Provided is a battery pack including flexible bus bars formed in a form in which a plurality of thin plates are stacked, having bent parts formed at the center thereof, and having both sides coupled to a positive electrode terminal and a negative electrode terminal protruding outwardly of battery modules to electrically connect electrode terminals of the battery modules to each other.

The present invention relates to a battery pack including batteries. A first current collector is provided for engaging with first electrodes of the batteries. The battery pack further includes a second current collector for engaging with second electrodes of the batteries. Fastening means is provided for fastening the current collectors together. Advantageously, the battery pack is assembled by fitting the current collectors together, without the need for screws or other threaded fasteners.