A Battery Modules For Electric Vehicles And Methods For Their Manufacture

Abstract: A method of making a battery module (100) comprising a plurality of interconnected cells (118) (e.g. pouch cells), each cell (118) having a plurality of terminals (118T1, 118T2), the method comprising: (i) arranging a plurality of cell groups (120), each group comprising 1, 2, 3 or more individual cells (118), e.g. in the form of a face-to-face cell stack or a side-by-side cell sub-array, into a side-by-side array, wherein pairs of cell terminals (118T1, 118T2) in adjacent respective cell groups (120) are adjacent one another, and preferably of opposite polarity; (ii) interconnecting the adjacent cell terminals (118T1, 118T2) within each respective pair via a or a respective busbar element (130B), e.g. of a flexible, braided, monometallic material, preferably by ultrasonic welding, so as to interconnect adjacent cell groups (120); and then, subsequent to step (ii), (iii) configuring the interconnected cell groups (120), e.g. by folding, into a faceto- face array to form the said battery module (100).

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