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.

Disclosed are a joint of a copper terminal and an aluminium conductor and an ultrasonic welding method thereof. One spacing metal layer is added between the copper terminal and the aluminium conductor, and firstly, the spacing metal layer is fixed at a welding end of a base material by means of a manner such as electroplating, pressure welding, electric arc spray welding or electromagnetic welding, and the three parts are then welded together by means of an ultrasonic welding manner. The welding method is suitable for the welding of various joints, the electrochemical corrosion resulting from the potential difference between the copper and aluminium electrodes can be effectively reduced, and the mechanical properties of the joint can be improved.

The present invention relates to a method of welding an electrode tab which welds an electrode tab and a current collecting layer by using a pulsed laser beam, and a cable type rechargeable battery including an electrode manufactured according to the same.

A stator of an electrical machine which has stator slots and conductor elements arranged in the stator slots, which conductor elements each have two conductor ends, is already known. A plurality of conductor ends, which are situated next to one another, of different conductor elements are in each case connected to one another by means of a weld connection, which is provided at the end sides of the conductor ends in question, without additional material. The conductor ends which are connected to one another in each case form a common rectangular conductor cross section which has a height H and a width B, wherein the height H corresponds to the height h of an individual cross section of the conductor ends, and the width B of the common conductor cross section is made up of the sum of the widths b of the individual cross sections of the conductor ends. The weld connection is in each case provided, as seen in the direction of the width B, between two non-melted edge sections of the outermost conductor ends. The weld cross section in the direction of the height H is comparatively low, this having effects on the long-tem mechanical strength of the weld connection and, during operation of the electrical machine, possibly causing temperature peaks at the weld connection as a result of a high current density. In the case of the stator according to the invention, the mechanical strength of the weld connection is increased. According to the invention, it is provided that the extent (L2) of the weld connection (8) in the direction of the height (H) is greater, at least in sections, than the height (H) of the common conductor cross section (9), and the surface of the weld connection (8) is consequently sunken in relation to the end sides (6) of the edge sections (10).

The disclosure provides an aluminized composite including a base material. The aluminized composite may also include a diffusion layer disposed over the base material. The aluminized composite may further include an aluminum material disposed over the diffusion layer.

A method for joining copper hairpins includes providing at least two ends to be joined to one another of the copper hairpins, and joining the copper hairpins. The copper hairpins are joined by laser beam welding with a machining beam having a wavelength of less than 1000 nm.

A method is described for welding a splice by way of an ultrasonic welding device, the ultrasonic welding device having a sonotrode for generating ultrasonic vibrations, an anvil, a first lateral element, a second lateral element and a compaction chamber, the height of which is adjustable by varying a distance between the sonotrode and the anvil and the width of which is adjustable by varying a distance between the first lateral element and the second lateral element.

A method of joining electrical connections together includes evaluating at least one weld joint between at least two substrates, determining mismatch between the at least two substrates, and welding the at least two substrates together with a multi-step welding process. The multi-step welding process includes compensating for mismatch between the at least two substrates by welding on both sides but not overlapping a joint line between the at least two substrates with a first welding step and increasing melt volume and penetration depth of a weld between the at least two substrates with a second welding step.

A welding device may include a frame, a welding assembly, a fastening bracket, a protective pressure plate, a first drive mechanism, and a second drive mechanism; the welding assembly may include a first welding head and a second welding head that are arranged opposite each other, and the first welding head may be fastened on the frame; the fastening bracket may be movably provided on the frame, and the second welding head may be fastened on the fastening bracket; the protective pressure plate may be fastened on the fastening bracket or the second welding head; and the first drive mechanism may be drivingly connected to the fastening bracket and configured to drive the fastening bracket so that the second welding head may reach a position of a welding point and the protective pressure plate may press against a to-be-welded member.

Embodiments are directed to contact plates configured to establish electrical bonds between battery cells in a battery module. In a first embodiment, the contact plate includes at least one primary conductive layer including a hole that is aligned with two or more terminals of two or more battery cells in a group of battery cells that are configured to be connected in parallel with each other, and a bonding connector configured to provide direct electrical bonds between the contact plate and the two or more terminals of the two or more battery cells. In a second embodiment, a contact plate includes at least one primary conductive layer and a set of bonding connectors made from at least one material that is selected to match at least one material used for the terminals of the at least one group of battery cells.