Various embodiments directed to manufacturing a battery assembly or battery pack are described. In some embodiments, the manufacturing process utilizes a welding jig to facilitate the placement and disposition of cell connection materials to battery cells when forming a battery assembly or pack. Using the jig, the connection materials can be fused to the cells using a laser welding process. In doing so, the process enables certain materials, typically unsuitable for welding processes (e.g., spot welding) to be utilized as connection materials between cells.

Various embodiments directed to manufacturing a battery assembly or battery pack are described. In some embodiments, the manufacturing process utilizes a welding jig to facilitate the placement and disposition of cell connection materials to battery cells when forming a battery assembly or pack. Using the jig, the connection materials can be fused to the cells using a laser welding process. In doing so, the process enables certain materials, typically unsuitable for welding processes (e.g., spot welding) to be utilized as connection materials between cells.

A device is described for connecting in parallel multiple battery cells (2) arranged in parallel to one another with respect to a joining axis using a contact plate (1) having individual passages (3). To enable a connection in parallel, which is reliable under periodic mechanical strains and nonetheless detachable, of individual battery cells (2) independently of their diameter and their relative location to the contact plate (1), wherein a simple assembling procedure can be maintained and a more flexibly designed serial interconnection of the battery cells can be enabled, it is proposed that each passage (3) is designed for the jacket-side enclosure of the battery cells (2) and comprises at least one contact tongue (4), which has on the passage side a contact body (5) protruding from the contact tongue (4) into the passage (3) in the form of a cut ovoid.

A battery pack includes battery cells arranged in a first direction, and a busbar assembly coupled to upper portions of the battery cells, the busbar assembly having a busbar electrically connected to the battery cells, a flexible substrate configured to measure a state information of the battery cells, and an insulating film surrounding the busbar and the flexible substrate.

A battery pack includes battery cells arranged in a first direction, and a busbar assembly coupled to upper portions of the battery cells, the busbar assembly having a busbar electrically connected to the battery cells, a flexible substrate configured to measure a state information of the battery cells, and an insulating film surrounding the busbar and the flexible substrate.

A busbar (10) for an electric battery (20) for electrically connecting a plurality of individual cells (21) of the battery (20) comprises at least two conductor layers (Lu, Lo) stacked one on top of the other. The conductor layers (Lu, Lo) are electrically insulated from each other except at specific contact points (P1. P2). A bottom conductor layer (Lu) comprises, at a first end, a main terminal (T) for connecting a power supply. A top conductor layer (Lo) is electrically connected to the bottom conductor layer (Lu) via at least a first contact point (P1) and a second contact point (P2). The electrical resistance along a first current path between the main terminal (T) and the first contact point (P1) is the same as the electrical resistance along a second current path between the main terminal (T) and the second contact point (P2).

A busbar (10) for an electric battery (20) for electrically connecting a plurality of individual cells (21) of the battery (20) comprises at least two conductor layers (Lu, Lo) stacked one on top of the other. The conductor layers (Lu, Lo) are electrically insulated from each other except at specific contact points (P1. P2). A bottom conductor layer (Lu) comprises, at a first end, a main terminal (T) for connecting a power supply. A top conductor layer (Lo) is electrically connected to the bottom conductor layer (Lu) via at least a first contact point (P1) and a second contact point (P2). The electrical resistance along a first current path between the main terminal (T) and the first contact point (P1) is the same as the electrical resistance along a second current path between the main terminal (T) and the second contact point (P2).

An aluminum bus bar includes an insulation portion having an oxide film insulation layer, and electric conduction portions having electric conductivity and disposed with the insulation portion being interposed therebetween. Also, a battery module includes the aluminum bus bar; a cell assembly having battery cells; an electric component electrically connected to the cell assembly by means of the aluminum bus bar; and a heatsink disposed at one side of the cell assembly to exchange heat with the cell assembly, and the insulation portion of the aluminum bus bar is disposed in contact with one surface of the heatsink.

An aluminum bus bar includes an insulation portion having an oxide film insulation layer, and electric conduction portions having electric conductivity and disposed with the insulation portion being interposed therebetween. Also, a battery module includes the aluminum bus bar; a cell assembly having battery cells; an electric component electrically connected to the cell assembly by means of the aluminum bus bar; and a heatsink disposed at one side of the cell assembly to exchange heat with the cell assembly, and the insulation portion of the aluminum bus bar is disposed in contact with one surface of the heatsink.

An embodiment of the present invention comprising of a conductive top layer with a plurality of terminals enabling battery connections to be made in series. An insulator middle layer with conductive material extending from the top terminals to the bottom terminals. A conductive bottom layer with a plurality of terminals enabling battery connections to be made to the output terminal or terminals. Output terminal or terminals enabling a load or additional lantern battery adapters to be connected either in series or parallel configuration.