Description:CURRENT COLLECTOR OF BATTERY PACK

TECHNICAL FIELD
[0001] The present disclosure generally pertains to battery technology, more specifically to the current collector of battery packs of an electric vehicle.
BACKGROUND
[0002] Electric vehicles (EVs) have rapidly gained prominence in the global automotive landscape, promising a sustainable transportation alternative to traditional fossil fuel-powered vehicles. At the core of such technological revolution is the battery pack, a complex assembly of individual battery cells. The aforesaid cells, when properly configured, provide the requisite power and energy density to propel the vehicle efficiently and effectively over extended distances.
[0003] Within the aforesaid battery packs, one critical component is the current collector, sometimes referred to as the busbar. Current collectors serve a pivotal role in connecting individual battery cells. The main function of current collectors is to facilitate the desired series and parallel connections to determine overall voltage and current output of the battery pack. Consequently, the design and performance of the current collector are paramount to the overall efficiency, reliability, and safety of the battery pack, and by extension, the electric vehicle itself.
[0004] Traditionally, resistance welding has been the favored technique for attaching battery cells to their associated current collectors. The resistance welding involves the application of pressure and electrical current to create a weld between the terminal of the battery cell and the current collector, thus establishing an electrical connection.
[0005] However, resistance welding is not without challenges, especially when considering the specific requirements of electric vehicle battery packs. A primary limitation arises from the thickness constraints of the materials involved. Specifically, the terminal thickness of the battery cells is typically about 0.2 mm. The thickness imposes a constraint on the current collector thickness, which also cannot exceed 0.2 mm to achieve effective resistance welding.
[0006] The choice of material for the current collector further increases complications. To achieve a robust and reliable weld, nickel has emerged as the favored material for current collectors. Such preference arises as many battery cell casings employ nickel-plated steel. Welding similar materials typically results in superior joint quality, and hence, the widespread use of nickel current collectors has become the industry standard.
[0007] However, this brings about another predicament. Given the increasing demands for power in modern electric vehicles, current collectors with a mere thickness of 0.2 mm made of nickel often fall short of delivering the necessary power requirements. Electric vehicles, with their need for rapid acceleration, fast charging, and high energy efficiency, require battery packs that can deliver high currents without significant resistive losses. A thin nickel current collector, while suitable for welding, might not be optimal in terms of electrical performance.
[0008] Moreover, the use of thin nickel current collectors can lead to other challenges. The nickel current collectors might be more susceptible to mechanical failures or breakages due to their limited thickness. Furthermore, such thin materials might not dissipate heat effectively, which is a significant concern given the thermal demands of EV battery packs. Overheating can degrade battery performance, reduce lifespan, and in extreme cases, pose safety risks.
[0009] In light of these challenges, there exists a need for an improved current collector design and attachment methodology. Such an advancement should ideally overcome the limitations of resistance welding, address the thickness constraints, and cater to the evolving power and performance requirements of electric vehicle battery packs. In pursuing this endeavor, the overall objective remains clear: to enhance the efficiency, reliability, and safety of electric vehicles, pushing the boundaries of sustainable transportation.
SUMMARY
[0010] The aim of the present disclosure is to provide a current collector of a battery pack of an electric vehicle that connects the cells of the battery pack to achieve the desired series and parallel connections as per the requirements. The aim of the disclosure is achieved by a current collector that enhances the performance of the battery pack by reducing voltage imbalance due to lower electrical resistance, and by bolstering mechanical strength, ensuring optimal resilience and efficient energy conduction.
[0011] In an embodiment, the present disclosure discloses a current collector of a battery pack of an electric vehicle, wherein the current collector comprises: a first base member comprising: a first set of openings disposed along a first side of a midline, wherein the midline is associated with a first longitudinal direction of the first base member; and a second set of openings disposed along a second side of the midline, wherein the second side is opposite to the first side; a second base member implemented as an elongated element having a third side and a fourth side, wherein the second base member is associated with a second longitudinal direction; multiple metal strips arranged, individually, with each of the first base member and the second base member, wherein each metal strip comprises a first series of tabs disposed along a fifth side of the metal strip and a second series of tabs disposed along a sixth side of the metal strip, and wherein each metal strip is arranged with: the first base member to cause alignment of: the first series of tabs with the first set of openings; the first series of tabs with the second set of openings; the second series of tabs with the first set of openings; or the second series of tabs with the second set of openings; and the second base member to cause positioning of: the first series of tabs along the third side; the first series of tabs along the fourth side; the second series of tabs along the third side; or the second series of tabs along the fourth side; wherein the metal strip is laser-welded, individually, through multiple laser-weld lines, to the first base member or the second base member, and wherein: the laser-weld lines are positioned parallelly to the multiple tabs along the first longitudinal direction or the second longitudinal direction, respectively; a length of each laser-weld line is in a range of 70% to 130 % of a width of the tab; and a distance between the weld line and a proximal edge corresponding to the first base member or the second base member is in a range of 5% to 70 % of the length of weld line.
[0012] In an embodiment, the first base member is fabricated from a first material and the second base member is fabricated from a second material and wherein each of the first material and the second material is selected, individually, from: aluminium, copper, silver, nickel, cupronickel.
[0013] In an embodiment, each metal strip is fabricated from a third material and wherein the third material is selected from: aluminium, copper, silver, nickel and cupronickel.
[0014] In an embodiment, the second base member is associated with at least two metal strips, wherein each metal strip is disposed on the same side of the second base member.
[0015] In an embodiment, the first set of openings is arranged parallelly to the second set of openings; and the first series of tabs is arranged parallelly to the second series of tabs.
[0016] In an embodiment, each first base member and each second base member comprises at a respective longitudinal end: a projection, and/or an end tab.

BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein.
[0018] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams.
[0019] FIG. 1 illustrates current collector of battery pack of an electric vehicle, in accordance with embodiments of the present disclosure;
[0020] FIG. 2 illustrates the placement of a soft pack within a battery pack of EV, in accordance with embodiments of the present disclosure;
[0021] FIG. 3 illustrates the multiple current collectors disposed on the top side of the battery pack, in accordance with embodiments of the present disclosure;
[0022] FIG. 4 represents an exploded view of battery pack, in accordance with embodiments of the present disclosure;
[0023] FIG. 5 illustrates the current collectors in bottom side of soft pack, in accordance with embodiments of the present disclosure;
[0024] FIG. 6 illustrates an exploded view of the current collectors, in accordance with embodiments of the present disclosure;
[0025] FIG. 7 illustrates the welding pattern used in current collectors, in accordance with embodiments of the present disclosure;
[0026] FIG. 8 illustrates the first base member welded with the metal strips, in accordance with embodiments of the present disclosure; and
[0027] FIG. 9 illustrates the second base member welded with the metal strips, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS
[0028] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
[0029] FIG. 1 illustrates a current collector of a battery pack of an electric vehicle, in accordance with embodiments of the present disclosure. The current collector 100 is fabricated with a first base member 102 comprising openings on either side of a midline (imaginary, not depicted in FIG. 1). The midline serves as a reference point, ensuring that openings are disposed in an optimum alignment for facilitating the flow of electrical currents. The current collector 100 also comprises a second base member 104 configured as an elongated element, the multiple metal strips 106-A1, 106-A2, 106-A3,….106-AN (collectively or individually referred as metal strips 106-A or metal strip 106-A) or/and any other known components of a busbar/current-collector apparatus/device.
[0030] In an embodiment, the first base member 102 may comprise a first set of openings, placed along a first side of the midline that is associated with a first longitudinal direction. The first base member 102 comprises a second set of openings, arranged at a second side of the midline (at the opposing side of the first set of openings). Such precise positioning of the first and second set of openings ensures uniform current distribution and also aids in integrating other components of the current collector 100.
[0031] In another embodiment, the current collector 100, incorporates the second base member 104, manifested as an elongated element. The elongated form facilitates a snug and optimized fit within the confines of the battery pack, making the most of available space. The second base member 104 comprises a third side and a fourth side, wherein the second base member 104 is associated with a second longitudinal orientation. The linear alignment offered by the elongated structure enables a range of interfacing options with the metal strips 106-A. Consequently, the elongated structure allows for multiple configurations and connections, ensuring that the current collector 100 can be integrated while maintaining optimal electrical connectivity and performance within the framework of the battery pack.
[0032] In an embodiment, the metal strips 106-A is characterized by a series of tabs along two opposing sides (namely a fifth side and a sixth side). For example, a first series of tabs are disposed along the fifth side and a second series of tabs are disposed along the sixth side, to enable alignment with the first base member 102 and/or the second base member 104. Such constructional flexibility ensures that the current collector 100 can be adapted to function in a wide range of battery pack configurations.
[0033] In an embodiment, when interfaced with the first base member 102, the metal strips 106-A, syncs the first series of tabs with either the first set of openings or the second set of openings. Additionally, the second series of tabs can also find alignment with either the first or second set of openings on the first base member 102. Such alignment enables a desired customization for the current collector 100 to ensure that the efficiency of the battery pack is always at the optimized level.
[0034] In an embodiment, the first base member is configured such that, upon engagement, the first series of tabs can be aligned with the first set of openings. Additionally, said first base member can be manipulated in a manner by which alignment of the aforementioned first series of tabs with the second set of openings is achieved. Similarly, alignment of the second series of tabs with the first set of openings can also be attained by the engagement of said first base member. Furthermore, the first base member facilitates alignment of said second series of tabs with the second set of openings. On the other hand, the second base member can be arranged in a way that, when engaged, positioning of the first series of tabs along a third side is achieved. Further to this, said second base member can be employed to achieve positioning of the first series of tabs along a fourth side. The same second base member is also adaptable to accommodate positioning of the second series of tabs along the third side. Optionally, the second base member causes the positioning of the second series of tabs along the fourth side. The versatility of the first and second base members is highlighted in the various alignment and positioning combinations described. By enabling four distinct alignment options using the first base member and four distinct positioning options using the second base member, a high degree of flexibility and adaptability is afforded to optimize functionality of current collector 100.
[0035] In another embodiment, the collaboration of metal strips 106-A with the second base member 104 allows for the positioning of the first series of tabs along either the third or fourth side. Additionally, the second series of tabs can also be positioned along the third or fourth side, ensuring that multiple configurations are possible. Such adaptability maximizes the conduction pathways and also ensures that the current collector 100 is resilient to operational stressors.
[0036] In an embodiment, the current collector 100 features the application of laser-welding to attach the metal strips 106-A to the first base member 102 and the second base member 104. Each metal strip 106-A is attached using multiple laser-weld lines with improved precision, strength, and long-term reliability. In electric vehicles, where temperature fluctuations and vibrations are common, such high-precision welding ensures that the current collector 100 remains steadfast in the function throughout its operational life.
[0037] In yet another embodiment, the laser-weld lines are systematically placed parallel to the multiple tabs and are aligned with either the first longitudinal direction or the second longitudinal direction. Such positioning enables optimal stress distribution across the current collector 100, minimizes the structural weaknesses and mitigation of potential failures. Such positioning means that the risks of deformations, misalignments, or fractures are significantly reduced, enhancing the overall durability of the current collector 100. For instance, in scenarios where uneven welding might result in stress concentration, ensuring parallel alignment minimizes such risks, promoting long-term reliability.
[0038] In an embodiment, the dimensions of the laser-weld lines enable optimal balance between weld strength and material usage. As an example, weld lines that are excessively long, might consume more energy during the welding process without proportionate gains in strength, whereas shorter welds might compromise structural integrity. In an aspect, the length of each of these laser-weld lines is a function of the width of the tab. The term “length of weld line” refers to the linear distance from a starting point to an endpoint of the laser-weld line. Specifically, the length of each laser-weld line can be in a range of 70% to 130% of the tab's width. The term “width of the tab” refers to the broadest measurement or extent of the tab from one side to the other side, at a right angle to the length of tab. For instance, if a tab (from either of the first series or second series) has a width of 100 units (this unit can be millimeters, centimeters, etc.), then the length of the laser-weld line can range from 70 units to 130 units. The proportional relationship (between length of weld line and width of tab) enables that weld covers a substantial portion of the tab, optimizing electrical connectivity and structural strength while preventing over-extension that might compromise the integrity of the tab or the adjoining structures. In an exemplary embodiment, the length of the weld line can range between 10 to 15 mm, 10 to 12 mm, 8 to 13.5 mm, 12 to 18 mm, 7 to 22 mm and the like. In an aspect, smaller weld lines having a length lesser than 70% (of tab width) might not provide the necessary bond strength, increasing the risk of the metal strips 106-A detaching from the base members under dynamic forces, leading to interruptions in current flow or even short circuits. On the other hand, weld lines exceeding 130 % (of tab width) can introduce thermal stresses due to a larger heated area during the welding process, possibly leading to warping, material degradation, or compromised connections. The specific length enables the welded connections to endure the dynamic operational conditions of the vehicle, from thermal expansions to high-frequency vibrations. By keeping the weld lines within the range, the current collector 100 remains resilient, ensuring consistent performance of the battery pack.
[0039] In an aspect, a first distance between the weld lines of two adjacent tabs (of either the first series of tabs or the second series of tabs) can be selected from 100% to 170% of the actual length of the weld line. For example, if the weld line extends for a length of 100 units (this unit can be millimeters, centimeters, etc.), the first distance between the weld lines of two adjacent tabs can range from 100 units to 170 units. The "first distance" denotes the space or gap that exists between the weld lines of one tab and neighboring tab thereof. The first distance can be critical for ensuring structural integrity, maintaining design specifications, or achieving desired functionality in the final product. In another aspect, a second distance between the weld line of the first series of tab and the second series of can be selected from 10% to 100% of the actual length of the weld line. For example, if the weld line extends for a length of 100 units (this unit can be millimeters, centimeters, etc.), the second distance can be range from 10 units to 100 units. The "second distance" pertains to the linear measurement or separation between the weld line of tab from the first series and the weld line of tab from the second series.
[0040] Furthermore, the positioning/ spatial relationship of the weld line relative to the edges of the tab ensures the stability and longevity of the weld, and avoids structural weaknesses or stress points. The weld line can be oriented parallel to the proximal edge of the first base member. A distance between the weld line and proximal edge can be within a range of 5% to 70% of the length of the weld line. For instance, a weld line that stretches over 100 units in length, the distance from this weld line to the proximal edge can be designed to lie between 5 units (5% of 100) and 70 units (70% of 100). The term “distance between the weld line and the proximal edge” refers to a perpendicular linear space or gap between the weld line to the proximal edge of the tab, corresponding to the first base member and/or second member of the current collector. Positioning the weld line too close to the proximal edge can jeopardize the tab's structural robustness. The heat generated from welding can cause localized thermal deformities. If the weld line is too close

the edge, it increases stresses on the current collector under the battery's operating conditions. Placing the weld line too adjacent to the edge can lead to warping, distortion, or even potential fractures. The minimum 5% distance (of weld line length) can prevent aforesaid problems. Weld lines in too close proximity to edges may result in less area for the dissipation of generated heat, leading to weld defects. An appropriately spaced distance ensures that the heat can disperse effectively, guarding against localized overheating which can degrade the structural integrity of the current collector. Smaller distance less than 5% may jeopardize the structural integrity of the current collector 100, making it susceptible to fractures or breaks, under dynamic load conditions, vibrations, or thermal fluctuations common in electric vehicle operations. Additionally, a minimal gap can increase the risk of weld spatter affecting the edges, leading to poor weld quality and reduced electrical conduction efficiency. Conversely, a distance greater than 70% might result in inefficient space utilization within the battery pack, reducing the available area for other critical components or pathways. The aforesaid condition can compromise the optimal arrangement and the overall compactness and efficiency of battery pack formation of the electric vehicle. In an exemplary embodiment, the distance between the edge and the weld line can be 1-3 mm, 1.5 mm, 1-2 mm, 2.5 mm, 3 mm, 3.5 mm and the like.
[0041] In another embodiment, the current collector 100 may employ precise dimensions in the welding process. The length of each laser-weld line surpasses the width of each tab in both the first and second series of tabs. By ensuring that the length of the weld line exceeds the width of the tab, a more secure and robust connection is established. The dimensions are essential in enhancing the structural integrity of the connections, ensuring that the connections remain resilient against dynamic loads, vibrations, or thermal fluctuations common in electric vehicle operations.
[0042] In an embodiment, the first base member 102 of current collector 100 can be fabricated from a distinct first material while the second base member 104 may utilize a different second material. Both the materials are individually chosen from a set comprising aluminium, copper, silver, nickel, cupronickel. The material highlights the significance of optimizing conductivity, durability, and resistance to corrosion within the battery pack of the electric vehicle. Depending on the requirements and specific applications, aluminum might be favored for the lightweight properties and good conductivity, copper for the excellent electrical conductivity, silver for the superior conductive capabilities, or cupronickel for the corrosion resistance in harsh environments.
[0043] In another embodiment, each metal strip 106-A within the current collector 100 may be fabricated from a specific third material that is selected from aluminium, copper, silver, nickel, cupronickel. The choice of nickel emphasizes the high resistance to oxidation and corrosion, ensuring longevity and consistent performance throughout the operational life of the battery pack. Conversely, cupronickel might be chosen for the combined strength, corrosion resistance, and moderate conductivity, making cupronickel a versatile choice suitable for various conditions that the electric vehicle might encounter.
[0044] In yet another embodiment, relating to the current collector 100, said second base member 104 can be characterized by the association with at least two metal strips 106-A. Each of such metal strip 106-A is disposed on the same side of said second base member 104. In the aforesaid configuration, the coexistence of the metal strips 106-A on a singular side of the second base member 104 enhances the potential for increased conductivity and efficient current collection. The precise positioning and disposition of the metal strips 106-A contribute to a streamlined design that could mitigate undue resistance or impedance challenges. Such structural arrangement of having the multiple metal strips 106-A on the same side of such second base member 104 is considered to optimize the functional attributes and performance of the current collector 100 in the intended applications. Further, the intentional alignment and arrangement of said metal strips 106-A ensure that the current collector 100 maintains the integrity and robustness during its operational lifecycle.
[0045] In an embodiment, the first set of openings on the first base member 102 can be arranged in parallel to the second set of openings. Similarly, the first series of tabs of metal strip 106-A can also be organized parallel to the second series of tabs. Such parallel arrangement ensures uniform distribution of electrical currents, minimizes resistance points, and streamlines the assembly process, ensuring that each component aligns with the other, promoting efficiency and reducing the possibility for assembly errors or malfunctions.
[0046] In an embodiment, both the first base member 102 and the second base member 104 of the current collector 100 feature specific configurational elements at the respective longitudinal ends. Each end incorporates a mating projection and an end tab. Such features are crucial for the modular assembly of the battery pack, allowing for seamless integration and connection with adjacent components or modules. The mating projection and end tab are instrumental in ensuring a snug fit, enhancing the overall structural stability of the battery pack and ensuring consistent electrical connectivity throughout the system.
[0047] The current collector 100 takes into account a plurality of factors to optimize the performance in the battery pack. Key parameters such as the direction of current flow, the cross-sectional area of the current collector 100 available for conduction, and the target operating temperatures of the battery pack aids in material selection. Specifically, portions of some current collectors are deliberately made from copper, due to inherently lower resistivity of copper in comparison to aluminum. Copper mitigates the resistance of the busbar and elevates the overall electrical performance. Due to superior conductivity properties of copper, more efficient, stable, and reliable energy transmission, vital for the optimal functionality and longevity of the battery pack within the electric vehicle can be achieved.
[0048] FIG. 2 illustrates the placement of a soft pack within a battery pack of EV, in accordance with embodiments of the present disclosure. The soft pack, composed of layered electrodes and electrolytes, can be encapsulated between the top and bottom casings. The top and bottom casings provide physical protection and also ensure insulation from external environmental factors, thereby enhancing the longevity and performance of the soft pack. The soft pack, top casing and bottom casing, achieves an efficient energy storage and transfer while maximizing the durability and safety of the battery pack in diverse operational scenarios.
[0049] FIG. 3 illustrates the multiple current collectors disposed on the top side of the battery pack, in accordance with embodiments of the present disclosure. The aluminium and copper materials significantly reduce the voltage imbalance of the battery pack. Such reduction can be attributed to the inherent lower electrical resistance of the aluminium and copper. To further enhance efficiency of the battery pack, the welding pattern employed in securing the current collectors amplifies the mechanical strength, and also optimizes the electrical resistance.
[0050] FIG. 4 represents an exploded view of the battery pack, in accordance with embodiments of the present disclosure. The battery pack integrates the first base member 102 and the second base member 104, whereas members 102 and 104 serve as structural anchors for the multiple metal strips 106-A, which are arrayed across the surface of the soft pack. The positioning of first base member 102, second base member 104 and metal strips 106-A enables the electrical and mechanical integrity of the battery pack, ensuring seamless energy transmission and enhanced durability of the battery pack.
[0051] FIG. 5 illustrates the current collectors in a bottom side of the soft pack, in accordance with embodiments of the present disclosure. As the illustration reveals, the soft pack incorporates the first base member 102 and the second base member 104, which are individually aligned with the multiple metal strips 106-A. Such arrangement optimizes electrical flow and mechanical stability within the battery pack.
[0052] FIG. 6 illustrates an exploded view of the current collectors, in accordance with embodiments of the present disclosure. The soft pack encompasses the first base member 102 and the second base member 104, individually, aligned with the multiple metal strips 106-A. A welding pattern, secures the metal strips 106-A to the first base member 102 and the second base member 104 and also enhances the integrity and efficiency of energy transfer within the battery pack.
[0053] FIG. 7 illustrates the welding pattern used in current collectors, in accordance with embodiments of the present disclosure. The metal strip 106-A is distinctly laser-welded through a succession of laser-weld lines, either to the first base member 102 or to the second base member 104. The laser-weld lines are oriented parallel to the multiple tabs, following either the first or the second longitudinal direction. The welding approach is fine-tuned down to specific measurements: each weld line flaunts a length falling within a 10 to 15 mm range. Additionally, spacing 1 to 3 mm can be maintained between each weld line and the nearest edge of the corresponding base member.
[0054] FIG. 8 illustrates the first base member 102 welded with the metal strips 106-A, in accordance with embodiments of the present disclosure. The each metal strip 106-A, is individually, secured to every distinct opening within the first base member 102. The individual attachment ensures precision, electrical conductivity and structural integrity between the first base member 102 and the metal strips 106-A. The one-to-one correspondence between each metal strip 106-A and the associated opening optimizes energy transfer, reduces chances of misalignment, and enhances the overall reliability of the battery pack.
[0055] FIG. 9 illustrates the second base member 104 welded with the metal strips 106-A, in accordance with embodiments of the present disclosure. As illustrated, a manner in which each metal strip 106-A, is affixed is illustrated. Each metal strip 106-A is individually welded, ensuring a secure bond with both the third and fourth sides of the second base member 104. The individual welding approach signifies the precision and diligence that goes into ensuring a robust and reliable connection. By utilising individual attachments, the current collector 100 aims to optimize energy flow and mechanical stability, thereby reducing points of failure and ensuring consistent energy transfer.

CLAIMS
What is claimed is:
1. A current collector of a battery pack of an electric vehicle, wherein the current collector comprises:
a first base member comprising:
a first set of openings disposed along a first side of a midline, wherein the midline is associated with a first longitudinal direction of the first base member; and
a second set of openings disposed along a second side of the midline, wherein the second side is opposite to the first side;
a second base member implemented as an elongated element having a third side and a fourth side, wherein the second base member is associated with a second longitudinal direction;
the multiple metal strips arranged, individually, with each of the first base member and the second base member, wherein each metal strip comprises a first series of tabs disposed along a fifth side of the metal strip and a second series of tabs disposed along a sixth side of the metal strip, and wherein each metal strip is arranged with:
the first base member to cause alignment of:
the first series of tabs with the first set of openings;
the first series of tabs with the second set of openings;
the second series of tabs with the first set of openings; or
the second series of tabs with the second set of openings; and
the second base member to cause positioning of:
the first series of tabs along the third side;
the first series of tabs along the fourth side;
the second series of tabs along the third side; or
the second series of tabs along the fourth side;
wherein the metal strip is laser-welded, individually, through multiple laser-weld lines, to the first base member or the second base member, and wherein:
the laser-weld lines are positioned parallelly to the multiple tabs along the first longitudinal direction or the second longitudinal direction, respectively;
a length of each laser-weld line is in a range of 70% to 130 % of a width of the tab; and
a distance between the weld line and a proximal edge corresponding to the first base member or the second base member is in a range of 5% to 70 % of the length of weld line.
2. The current collector as claimed in claim 1, wherein the first base member is fabricated from a first material and the second base member is fabricated from a second material and wherein each of the first material and the second material is selected, individually, from: aluminium, copper, silver, nickel, cupronickel.
3. The current collector as claimed in claim 1, wherein each metal strip is fabricated from a third material and wherein the third material is selected from: aluminium, copper, silver, nickel and cupronickel.
4. The current collector as claimed in claim 1, wherein the second base member is associated with at least two metal strips, wherein each metal strip is disposed on the same side of the second base member.
5. The current collector as claimed in claim 1, wherein:
a. the first set of openings is arranged parallelly to the second set of openings; and
b. the first series of tabs is arranged parallelly to the second series of tabs.
6. The current collector as claimed in claim 1, wherein each first base member and each second base member comprises at a respective longitudinal end: a projection, an end tab.

CLAIMS
What is claimed is:
1. A current collector of a battery pack of an electric vehicle, wherein the current collector comprises:
a first base member comprising:
a first set of openings disposed along a first side of a midline, wherein the midline is associated with a first longitudinal direction of the first base member; and
a second set of openings disposed along a second side of the midline, wherein the second side is opposite to the first side;
a second base member implemented as an elongated element having a third side and a fourth side, wherein the second base member is associated with a second longitudinal direction;
the multiple metal strips arranged, individually, with each of the first base member and the second base member, wherein each metal strip comprises a first series of tabs disposed along a fifth side of the metal strip and a second series of tabs disposed along a sixth side of the metal strip, and wherein each metal strip is arranged with:
the first base member to cause alignment of:
the first series of tabs with the first set of openings;
the first series of tabs with the second set of openings;
the second series of tabs with the first set of openings; or
the second series of tabs with the second set of openings; and
the second base member to cause positioning of:
the first series of tabs along the third side;
the first series of tabs along the fourth side;
the second series of tabs along the third side; or
the second series of tabs along the fourth side;
wherein the metal strip is laser-welded, individually, through multiple laser-weld lines, to the first base member or the second base member, and wherein:
the laser-weld lines are positioned parallelly to the multiple tabs along the first longitudinal direction or the second longitudinal direction, respectively;
a length of each laser-weld line is in a range of 70% to 130 % of a width of the tab; and
a distance between the weld line and a proximal edge corresponding to the first base member or the second base member is in a range of 5% to 70 % of the length of weld line.
2. The current collector as claimed in claim 1, wherein the first base member is fabricated from a first material and the second base member is fabricated from a second material and wherein each of the first material and the second material is selected, individually, from: aluminium, copper, silver, nickel, cupronickel.
3. The current collector as claimed in claim 1, wherein each metal strip is fabricated from a third material and wherein the third material is selected from: aluminium, copper, silver, nickel and cupronickel.
4. The current collector as claimed in claim 1, wherein the second base member is associated with at least two metal strips, wherein each metal strip is disposed on the same side of the second base member.
5. The current collector as claimed in claim 1, wherein:
a. the first set of openings is arranged parallelly to the second set of openings; and
b. the first series of tabs is arranged parallelly to the second series of tabs.
6. The current collector as claimed in claim 1, wherein each first base member and each second base member comprises at a respective longitudinal end: a projection, an end tab.

, C , Claims:CLAIMS
What is claimed is:
1. A current collector of a battery pack of an electric vehicle, wherein the current collector comprises:
a first base member comprising:
a first set of openings disposed along a first side of a midline, wherein the midline is associated with a first longitudinal direction of the first base member; and
a second set of openings disposed along a second side of the midline, wherein the second side is opposite to the first side;
a second base member implemented as an elongated element having a third side and a fourth side, wherein the second base member is associated with a second longitudinal direction;
the multiple metal strips arranged, individually, with each of the first base member and the second base member, wherein each metal strip comprises a first series of tabs disposed along a fifth side of the metal strip and a second series of tabs disposed along a sixth side of the metal strip, and wherein each metal strip is arranged with:
the first base member to cause alignment of:
the first series of tabs with the first set of openings;
the first series of tabs with the second set of openings;
the second series of tabs with the first set of openings; or
the second series of tabs with the second set of openings; and
the second base member to cause positioning of:
the first series of tabs along the third side;
the first series of tabs along the fourth side;
the second series of tabs along the third side; or
the second series of tabs along the fourth side;
wherein the metal strip is laser-welded, individually, through multiple laser-weld lines, to the first base member or the second base member, and wherein:
the laser-weld lines are positioned parallelly to the multiple tabs along the first longitudinal direction or the second longitudinal direction, respectively;
a length of each laser-weld line is in a range of 70% to 130 % of a width of the tab; and
a distance between the weld line and a proximal edge corresponding to the first base member or the second base member is in a range of 5% to 70 % of the length of weld line.
2. The current collector as claimed in claim 1, wherein the first base member is fabricated from a first material and the second base member is fabricated from a second material and wherein each of the first material and the second material is selected, individually, from: aluminium, copper, silver, nickel, cupronickel.
3. The current collector as claimed in claim 1, wherein each metal strip is fabricated from a third material and wherein the third material is selected from: aluminium, copper, silver, nickel and cupronickel.
4. The current collector as claimed in claim 1, wherein the second base member is associated with at least two metal strips, wherein each metal strip is disposed on the same side of the second base member.
5. The current collector as claimed in claim 1, wherein:
a. the first set of openings is arranged parallelly to the second set of openings; and
b. the first series of tabs is arranged parallelly to the second series of tabs.
6. The current collector as claimed in claim 1, wherein each first base member and each second base member comprises at a respective longitudinal end: a projection, an end tab.