A method of manufacturing a rechargeable battery includes continuously supplying a first electrode plate, the first electrode plate including a plurality of first active material portions with gaps therebetween on a first current collector, continuously supplying a first separator and a second separator to respective surfaces of the first electrode plate, bending the first electrode plate with the first and second separators to form a zigzag structure with bent portions, supplying a second electrode plate to an inside of each bent portion of the zigzag structure, the second electrode plate including a second active material portion on a second current collector, aligning and stacking the first electrode plate, the first separator, the second separator, and the second electrode plate, and taping the aligned and stacked first electrode plate, first separator, second separator, and second electrode plate at an outermost side thereof.

A swelling tape for filling a gap and a method of filling a gap are provided. The swelling tape can be applied within the gap having a fluid to realize a 3D shape thereby filling the gap, and be used to fix a subject forming the gap as necessary.

A polymer battery module packaging sheet includes, as essential components, a base layer (61), an aluminum layer (62), chemical conversion coatings (64a, 64b) coating the opposite surfaces of the aluminum layer (62), and an innermost layer (63). The chemical conversion coatings (64a, 64b) are formed by processing the opposite surfaces of the aluminum layer (62) by a phosphate treatment method. The base layer (61) and the innermost layer (63) are bonded to the chemical conversion coatings (64a, 64b) of the aluminum layer (62) with adhesive layers (65a, 65b), respectively.

A swelling tape for filling a gap and a method of filling a gap are provided. The swelling tape can be applied within the gap having a fluid to realize a 3D shape thereby filling the gap, and be used to fix a subject forming the gap as necessary.

A bus bar including a first end comprising a first material and a second end comprising a second material and a method of manufacture are provided. The first end is designed to be coupled to a terminal of a first battery cell of a battery module and includes a first collar disposed on the first end designed to receive and surround the terminal of the first battery cell of the battery module. The second end is designed to be coupled to a terminal of a second battery cell of the battery module and includes a second collar disposed on the second end designed to receive and surround the terminal of the second battery of the battery module. The first and second batteries of the battery module are adjacent to one another. Moreover, the bus bar includes a joint electrically and mechanically coupling the first end and the second end.

A battery module includes a housing, a plurality of battery cells disposed in the housing, and a printed circuit board (PCB) assembly disposed in the housing. The PCB assembly includes a PCB and a shunt disposed across a first surface of the PCB. A second surface of the shunt directly contacts the first surface of the PCB, and the shunt is electrically coupled between the battery cells and a terminal of the battery module.

A system includes a lid disposed over battery cells in a battery module. The lid includes flexible fingers, and each of the flexible fingers aligns with a corresponding one of the battery cells. Each of the flexible fingers is configured to exert a downward force against the corresponding one of the battery cells, and the flexible fingers are configured to accommodate varying heights of the battery cells.

A battery module may include a housing, a plurality of battery cells disposed in the housing, a battery terminal extending from the battery module for coupling the battery module with electrical components in the vehicle, and a contactor. A voltage supplied to a relay coil in the contactor may generate a magnetic field to actuate a contactor switch. The battery module may also include a printed circuit board (PCB) disposed in the housing. The PCB may include a relay control circuit configured to control a current flowing across the relay coil, and the relay control circuit may operate in a pull-in mode to transition the contactor switch into a closed position and in a hold mode to maintain the contactor switch in the closed position.

A battery module includes a housing, a plurality of battery cells disposed in the housing, and a printed circuit board (PCB) assembly disposed in the housing. The PCB assembly includes a PCB and a shunt disposed across a first surface of the PCB. A second surface of the shunt directly contacts the first surface of the PCB, and the shunt is electrically coupled between the battery cells and a terminal of the battery module.

A battery module includes a lower housing and a plurality of battery cells. The plurality of battery cells are electrically coupled together to produce a voltage. A lid assembly is disposed over the battery cells and is coupled to the lower housing. The lid assembly includes a lid and a plurality of bus bar interconnects mounted on the lid. A printed circuit board (PCB) assembly is disposed on and coupled to the lid assembly, and the PCB assembly includes a PCB. A cover is disposed over and coupled to the lower housing to hermetically seal the battery module.