Busbar forming method and folded busbar

Abstract

This disclosure provides a "busbar forming method and folded busbar". An exemplary busbar forming method includes, among other things, folding a sheet of material to form a plurality of creases that divide the sheet into a plurality of segments. The method also includes identifying a desired size of a terminal receiving recess in the busbar. In response to the desired size, the method folds at least some of the segments relative to each other around at least some of the creases according to a first process or a different second process. An exemplary battery assembly includes, among other things, a busbar formed from a sheet of material. The busbar has a terminal receiving recess. Creases are formed within the sheet that divide at least a portion of the sheet into a plurality of segments. Some of the segments are folded relative to each other around at least some of the creases to provide the terminal receiving recess in the busbar.

Description

Technical Field

[0001] This disclosure relates generally to busbars, and more specifically to sheets of material that can be folded to provide busbars having a first configuration or another configuration. Background Technology

[0002] Typically, electrified vehicles differ from conventional motor vehicles because they are selectively driven using one or more battery-powered electric motors. Conventional motor vehicles, in contrast, are driven solely by an internal combustion engine. Electrified vehicles can use electric motors instead of, or in addition to, an internal combustion engine.

[0003] The battery pack of an electrified vehicle may include multiple battery cells arranged in one or more battery arrays. Busbars are used to distribute power to and from the battery cells, and to and from the battery pack. Busbars are typically coupled to the terminals of the battery cell assembly, but may alternatively or additionally be coupled to other areas. Summary of the Invention

[0004] The busbar forming method according to an exemplary aspect of this disclosure includes, among other things, folding a sheet of material to form a plurality of creases that divide the sheet into a plurality of segments. The method further includes identifying a desired size of a terminal receiving recess in the busbar; and, in response to the desired size, folding at least some of the segments relative to each other around at least some of the creases, according to a first process or a different second process.

[0005] In another non-limiting embodiment of the aforementioned method, each of the creases extends linearly along a direction transverse to the longitudinal axis of the sheet.

[0006] In another non-limiting embodiment of any of the foregoing methods, the creases are distributed along the longitudinal axis of the sheet, and each crease extends from a first transverse side of the sheet to the opposite second transverse side of the sheet.

[0007] In another non-limiting embodiment of any of the foregoing methods, the segments are each of equal size.

[0008] In another non-limiting embodiment of any of the foregoing methods, the crease includes at least partially perforating the sheet to form the crease.

[0009] In another non-limiting embodiment of any of the foregoing methods, both the first and second processes include folding some of the same segments relative to each other around some of the same creases.

[0010] In another non-limiting embodiment of any of the foregoing methods, the creases are distributed such that the tool's punch can fold the sheet according to the first process, and the same punch can fold the sheet according to the second process.

[0011] In another non-limiting embodiment of any of the foregoing methods, a portion of the terminal receiving recess provided by the busbar includes a bottom and opposing sides. At least one of the opposing sides includes some of the segments that are folded against each other.

[0012] Further non-limiting embodiments of any of the foregoing methods include: after the folding, providing a portion of the terminal receiving groove that clamps the busbar to clamp a first number of battery terminal tabs when the desired opening size of the terminal receiving groove is a first size, and providing the portion of the terminal receiving groove that clamps the busbar to clamp a different second number of battery terminal tabs when the desired opening size of the terminal receiving groove is a different second size.

[0013] In another non-limiting embodiment of any of the foregoing methods, the busbar extends along a longitudinal axis, and the clamping includes opposing axial sides of the portion of the busbar that provides the terminal receiving groove in direct contact with the busbar.

[0014] In another non-limiting embodiment of any of the foregoing methods, the terminal receiving groove is a first terminal receiving groove. The method further includes folding at least some of the segments relative to each other around some of the creases to provide a second terminal receiving groove in the busbar spaced apart from the first terminal receiving groove.

[0015] Further non-limiting embodiments of any of the foregoing methods include: clamping the first terminal recess and the second terminal recess to corresponding first and second sets of battery terminal tabs, and using a portion of the busbar extending between the first and second terminal recesses as a spring to accommodate movement of the first and second sets of battery terminal tabs relative to each other during operation.

[0016] A battery assembly according to another exemplary aspect of this disclosure includes, among other things, a busbar formed of a sheet of material. The busbar has terminal receiving recesses. Creases are formed within the sheet, dividing at least a portion of the sheet into multiple segments. Some of the segments are folded relative to each other around at least some of the creases to provide the terminal receiving recesses in the busbar.

[0017] In another non-limiting embodiment of the aforementioned assembly, the terminal receiving recess is a first terminal receiving recess having a first size. At least some of the segments are foldable relative to each other around at least some of the creases to provide a busbar having a second terminal receiving recess having a different second size.

[0018] In another non-limiting embodiment of any of the foregoing assemblies, the plurality of segments are of equal size.

[0019] In another non-limiting embodiment of any of the foregoing assemblies, at least some of the creases around which some of the segments can be folded to provide a busbar having the terminal receiving groove of the first size are the same as the creases around which some of the segments can be folded to provide a busbar having the terminal receiving groove of the second size.

[0020] In another non-limiting embodiment of any of the foregoing assemblies, each of the creases extends transversely to the longitudinal axis of the sheet, and the creases are distributed along the longitudinal axis such that the plurality of creases divide the sheet into a plurality of equal-sized segments.

[0021] In another non-limiting embodiment of any of the foregoing assemblies, the crease is the area of ​​at least partial perforation of the material sheet.

[0022] In another non-limiting embodiment of any of the foregoing assemblies, at least one terminal of the battery is clamped within the terminal receiving recess.

[0023] In another non-limiting embodiment of the aforementioned assembly, at least one terminal includes a first terminal tab extending a first distance from the outermost housing of the first battery cell. The assembly also includes a second terminal tab extending a greater second distance from the outermost housing of the second battery cell, such that a portion of the first terminal tab outside the housing is longer than a portion of the second terminal tab outside the housing.

[0024] The embodiments, examples, and alternatives described in the foregoing paragraphs, claims, or the following specification and drawings, including any of their aspects or individual features, may be used independently or in any combination. Features described in connection with one embodiment may be applied to all embodiments unless such features are incompatible. Attached Figure Description

[0025] Various features and advantages of the disclosed examples will become apparent to those skilled in the art from the specific embodiments described herein. The accompanying drawings of the specific embodiments can be briefly described as follows:

[0026] Figure 1A schematic diagram of the powertrain system of an electrified vehicle is shown.

[0027] Figure 2 Shown from Figure 1 A magnified view of a selected portion of the battery cell array of the battery pack.

[0028] Figure 3 The diagram shows a sheet of material used to form a busbar, which will... Figure 2 Some battery cells are electrically coupled together.

[0029] Figure 4 This is shown after the sheet has been folded to form multiple creases that divide the sheet into sections. Figure 3 Sheet material.

[0030] Figure 5A A close-up view of an area having a crease according to an exemplary embodiment is shown.

[0031] Figure 5B A close-up view of an area having a crease according to another exemplary embodiment is shown.

[0032] Figure 5C A close-up view of an area having a crease according to yet another exemplary embodiment is shown.

[0033] Figure 5D A close-up view of an area having a crease according to yet another exemplary embodiment is shown.

[0034] Figures 6 to 11 The steps in the first process are shown, which will have information from... Figure 4 The creases in the material sheet are formed into a busbar with a first configuration, and then the busbar with the first configuration is fastened to... Figure 2 Terminal inserts of selected battery cells within the array.

[0035] Figure 12 Shown from Figures 6 to 11 A perspective view of a busbar with a first configuration, the busbar being fastened to a source... Figure 2 The array of battery cells has three terminal inserts.

[0036] Figures 13 to 17 The steps in the second process are shown, which will have information from... Figure 4 The creased sheet is formed into a busbar with a second configuration, and then the busbar with the second configuration is fastened to... Figure 2 Terminal inserts of selected battery cells within the array.

[0037] Figure 18 Shown from Figures 13 to 17 A perspective view of a busbar with a second configuration, the busbar being fastened to a source... Figure 2 The array of battery cells has six terminal inserts.

[0038] Figures 19 to 25 The diagram illustrates a step in another process, which involves forming a sheet to provide a busbar with a third configuration, and then fastening the busbar to... Figure 2 Terminal inserts of selected battery cells within the array.

[0039] Figure 26 Shown from Figures 19 to 25 A perspective view of a busbar with a third configuration, the busbar being fastened to a source... Figure 2 The array of battery cells has a first group of three terminal inserts and a second group of three terminal inserts.

[0040] Figure 27 This illustrates securing multiple buses with a third configuration to... Figure 27 The battery cell array in the array has terminal inserts before the battery cell array and the multiple from Figures 19 to 26 A top view of the bus with a third configuration. Detailed Implementation

[0041] This disclosure details battery cells for supplying and receiving power to and from traction batteries in electrified vehicles, as well as busbars for distributing power therein.

[0042] Specifically, busbars can be fabricated from sheet material to have multiple configurations. Various configurations facilitate coupling the busbar to different numbers of terminal blocks. Providing busbars with different configurations from sheet material of similar size can reduce construction complexity, among other things. Fabrication of the sheet material may include folding the sheet to effectively increase its thickness.

[0043] See Figure 1 The exemplary electrified vehicle 10 includes a battery pack 12, a motor 14, and a pair of wheels 16. The exemplary electrified vehicle 10 is a fully electric vehicle.

[0044] The power from battery pack 12 can be used to drive motor 14. In response, motor 14 can generate torque to drive wheels 16. Battery pack 12 can be considered as a relatively high-voltage traction battery pack.

[0045] Although depicted as a pure electric vehicle, it should be understood that the concepts described herein are not limited to pure electric vehicles and can be extended to other types of electrified vehicles. Electrified vehicle 10 can be, for example, a hybrid electric vehicle that can selectively drive wheels 16 using torque provided by an internal combustion engine (instead of an electric motor or in addition to an electric motor). Other electrified vehicles may include, but are not limited to, plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs), and fuel cell vehicles.

[0046] See Figure 2 Continue to refer to Figure 1 The battery pack 12 may include an array 20 of battery cells 22. The battery cells 22 may be arranged along the array axis A. A Arranged in array 20. One or more of array 20 are then housed within a housing to provide battery pack 12.

[0047] Figure 2 Nine battery cells 22 within array 20 are shown. Additional cells can be added to array 20 as needed.

[0048] In this exemplary embodiment, the battery cell 22 is a lithium-ion pouch battery. Each battery cell 22 includes an electrode structure held within a housing 26, a positive terminal tab 30, and a negative terminal tab 34. The axial width of the battery cell 22 can be, for example, 15 mm to 17 mm.

[0049] Referring to one of the battery cells 22, terminal tabs 30 and 34 extend from opposite lateral sides of the battery cell 22. In other examples, one or both of terminal tabs 30 and 34 may alternatively extend from the other side of the battery cell 22. Terminal tabs 30 and 34 may also extend from a common side of the battery cell 22.

[0050] In an exemplary embodiment, a plurality of busbars 38 are each clamped to one or more of terminal tabs 30 and 34. Figure 2 In the diagram, one of the busbars 38 is shown before being clamped to the three terminal tabs 30, while another busbar 38 is shown clamping the three terminal tabs 30. Clamping the busbar 38 to the terminal tabs 30 electrically couples the busbar 38 and the terminal tabs 30 together. In this example, each busbar 38 clamps three terminal tabs 30 together to connect those terminal tabs 30 in parallel.

[0051] For clarity of the attached image, Figure 2 Only two busbars 38 are shown. The fully assembled array 20 may include additional busbars 38 for connection to the remaining terminal tabs 30 and 34. Busbars 38 can electrically connect the battery cells 22 together in series or parallel, and can be electrically connected to other structures as needed.

[0052] Busbar 38 includes a terminal receiving recess 42, which is generally defined by a base plate 46 and a pair of opposing walls 50 and 54 extending from the opposite side of the base plate 46. When busbar 38 is fastened to terminal insert 30, terminal insert 30 is placed within the terminal receiving recess 42. The walls 50 and 54 are then pressed together to clamp the terminal insert 30.

[0053] In an exemplary embodiment, busbar 38 is configured such that wall 50 comprises three layers of material sheets, and wall 54 comprises two layers of material sheets 60. Base plate 46 comprises a single layer of material sheet. The multiple layers within walls 50 and 54 are provided by folding the material sheets.

[0054] Similarly, in the exemplary embodiment, the thickness T of the material sheet 60 is a thickness suitable for handling the current requirements of the battery pack 12. However, in some other embodiments, the thickness T is less than the thickness suitable for handling the current requirements of the battery pack 12. In such other embodiments, folding the material sheet 60 can provide the thickness required to handle the current requirements of the battery pack 12. That is, in some embodiments, a wall 54 having a thickness of 2T after folding can be suitable for handling the current requirements of the battery pack 12, but if the wall 54 is instead a single layer having a thickness T, it is not suitable for handling the current requirements of the battery pack 12.

[0055] refer to Figure 3 The material sheet 60 is either stamped or supplied by another process. The material sheet 60 is along the longitudinal axis L. m Extended. The material sheet 60 has a thickness T. In some examples, the thickness T is 1.2 mm to 1.5 mm. The thickness T can be a thickness suitable for handling the current requirements of the battery pack 12.

[0056] Figure 4 The diagram shows a sheet of material 60 after it has been folded to form multiple creases 68. The creases 68 are intentionally weakened areas of the sheet of material 60. Among other things, the creases 68 facilitate folding the sheet of material 60 to provide various busbar configurations.

[0057] In an exemplary embodiment, the crease 68 is linear and runs transverse to the longitudinal axis L of the material sheet 60. m The creases 68 extend generally from the first transverse side 72 of the material sheet 60 to the opposite second transverse side 76 of the material sheet 60.

[0058] Crease 68 can be multiple perforations 80 within the material sheet 60, such as Figure 5A As shown. For example, a punching process can be used to form perforations 80. Each perforation 80 leads to the upward-facing side 84 of the material sheet 60. Each perforation 80 extends longitudinally from the upward-facing side 84 by a distance approximately 25% to 40% of the thickness T of the material sheet 60. In another example, the perforation 80 extends completely through the material sheet 60, such that the perforation 80 also leads to the downward-facing side 88 of the material sheet 60, which is opposite to the upward-facing side 84.

[0059] Another example of crease 68 is in Figure 5BAs shown, the crease 68 is provided by the compression region 92 of the material sheet 60. A press can be used to form the compression region 92.

[0060] Figure 5C Another example of crease 68 is shown, wherein perforation 96 leads to the upward-facing side 84 of material sheet 60, and another perforation 100 leads to the downward-facing side 88 of material sheet 60.

[0061] Figure 5D Another example of crease 68 is shown, wherein the crease is provided by compression region 104 in the upward-facing side 84 of the material sheet 60, and additionally by compression region 108 formed in the downward-facing side 88 of the material sheet 60.

[0062] See you again Figure 4 In an exemplary embodiment, creases 68 are distributed along the material sheet 60, such that the material sheet 60 is divided into a plurality of nominally equal-sized segments 112. Each crease 68 represents one of the segments 112 relative to the longitudinal axis L of the material sheet 60. m The boundary between axially adjacent segments 112.

[0063] In another example, the entire material sheet 60 is not divided into equally sized segments. For example, the segment at the axial end of the material sheet may be larger than the remaining segments. The larger segments are indicated by dashed lines 116.

[0064] For reference Figures 6 to 12 The material sheet 60 with creases 68 is folded according to the first process to provide a terminal receiving groove 42. Figure 2 Busbar 38.

[0065] Each section 112 initially as Figure 6 The sections are folded relative to each other. The folding of some sections relative to other sections in section 112 is a fold around crease 68. Similarly, crease 68 prompts a fold in the desired area.

[0066] Folding segments 112 relative to each other can be achieved using a tool (e.g., a punch and die). For example, the dimensions of the punch may typically correspond to the axial length of a segment 112. The position of the material sheet 60 is then manipulated relative to the punch and die to fold the individual segments 112. Figure 6 In the position shown.

[0067] Next, the selected segment 112 is as follows: Figure 7 and Figure 8 The structure is folded as shown to provide a busbar 38 having a base plate 46, walls 50 and 54. Figure 7 and Figure 8 The folding of progressively represented segments can be used to form Figure 6 This can be achieved by using the same configured tools (e.g., the same punch and die) or by using other suitable molds.

[0068] like Figure 9 As shown, busbar 38 has a terminal receiving recess 42 with a width of W. During assembly, busbar 38 moves along direction D and terminal tabs 30 are positioned within the terminal receiving recess 42. It is desired that busbar 38 is electrically coupled to three terminal tabs 30. Therefore, the size of the terminal receiving recess 42 is set such that the width W corresponds to a width suitable for accommodating the three terminal tabs 30.

[0069] like Figure 10 and Figure 11 As shown, after the terminal insert 30 is positioned within the terminal receiving groove 42, the busbar 38 is clamped (and optionally welded) against the terminal insert 30 along direction C to hold the terminal insert 30 and the busbar 38 together and electrically couple the busbar 38 to the terminal insert 30. During clamping, the clamp can directly contact the opposite axial sides of the busbar 38. The direction is aligned with the longitudinal axis of the array 20 of battery cells 22. Figure 2 After clamping, bus 38 is electrically coupled to terminal insert 30 of battery cell 22, as shown below. Figure 12 As shown.

[0070] Instead of clamping, or in addition to clamping, busbar 38 can be welded (typically ultrasonically or laser-welded) or bolted to terminal plate 30. Depending on the width of terminal plate 30 and retention force requirements, multiple weld joints can be added (typically two to three to ensure good contact). If bolting is used, holes can be punched through busbar 38 and terminal plate 30 before bolting. The torque on the bolts can be driven by retention force requirements.

[0071] In some examples, it is desirable to use busbar 38 to clamp different numbers of terminal tabs 30 or 34. To provide a busbar suitable for clamping, for example, six terminal tabs 30 or 34, it can be based on... Figures 13 to 18 Different second processes form with Figure 4 The material sheet 60 with the crease 68 shown is provided to have a greater than Figure 9 The width W of the terminal receiving groove 42 shown is... a Busbar 38a of terminal receiving groove 42a.

[0072] The second process includes the initial... Figure 13 The folded material sheet 60 is shown, and then the selected section 112 is folded again relative to the other sections 112 to provide Figure 14 The terminal receiving groove 42a is shown.

[0073] Used to form such Figure 14The mold for busbar 38a shown can be used to form Figure 8 The mold for busbar 38 shown is the same. This is due, among other things, to the fact that the creases 68 of busbar 38 and busbar 38a are in the same position. After providing busbar 38a, the busbar... Figure 15 and Figure 16 As shown, it moves above the terminal insert 30 of the battery cell 22 and is then clamped to... Figure 17 In the final position shown.

[0074] In this example, terminal tab 30' is the outermost terminal tab axially relative to the longitudinal axis of array 20. Terminal tab 30' extends further from the housing 26 of the corresponding battery cell 22 than terminal tab 30'', which is closer to the axial center of the terminal receiving recess 42a. Terminal tab 30'' extends further from the housing 26 of the battery cell 22 than the center terminal tab 30''. Changing the length of the terminal tabs 30 so that the outer terminal tab 30' is longer than the inner terminal tabs 30'' and 30'' helps ensure that the terminal tab 30' is properly held and clamped by the busbar 38a after clamping.

[0075] See now Figures 19 to 26 In another example, the busbar 38b is formed according to a different process. Initially, the material sheet 60b is folded along its longitudinal axis to provide a double-layer material, such as... Figure 20 As shown. Creases can be formed along the longitudinal axis to facilitate this folding.

[0076] This can then form a double-layer material 60b to include multiple creases 68b, such as Figure 21 As shown. Crease 68b can be similar to Figure 4 The crease in the middle is 68.

[0077] Then, at least some of the segments 112b formed by crease 68b are folded relative to each other, as follows: Figure 22 As shown. This forms two separate terminal receiving recesses 42b within busbar 38b. Next, the section 112b between the terminal receiving recesses 42b is formed with an arcuate configuration, as shown... Figure 23 As shown. The busbar 38b formed from the material sheet 60b therefore includes two terminal recesses 42b connected by the arcuate region 120.

[0078] The bow-shaped region 120 can be formed using a semi-cylindrical tool that presses the segment 112b between the terminal receiving grooves 42 into a pre-formed surface to control the shape of the bow. Forming the bow-shaped region 120 can substantially include a stamping process.

[0079] Then the busbar 38 can be fastened to the terminal insert 30 of the battery cell 22, such as Figures 24 to 26As shown. In this exemplary embodiment, each terminal receiving groove 42b clamps and secures it to the three terminal inserts 30.

[0080] After the busbar 38b is secured, the arcuate region 120 can accommodate relative movement between terminal tabs 30 received in one terminal receiving recess 42b and terminal tabs 30 received in another terminal receiving recess 42b. For example, the arcuate region 120 can act as a spring that bends as the terminal tab 30 held in one terminal receiving recess 42b moves axially relative to the terminal tab 30 held in the other terminal receiving recess 42b. Among other things, the bending can accommodate some relative axial movement to prevent such movement from disrupting the connection between the terminal tabs 30 and the busbar 38b. Relative movement may be due to the expansion and contraction of the battery cell 22 during operation.

[0081] See now Figure 27 Several buses 38b may be arranged around array 20b to provide the desired electrical connection between the groups of battery cells 22. Buses 38 and 38a may be distributed around array 20 in a similar manner.

[0082] The disclosed examples feature a busbar forming method that utilizes different processes to form similar-sized sheets of material into busbars with various configurations. These various configurations can be used to adapt to and fasten to different numbers of battery terminal tabs and to accommodate various environments within a battery pack. Providing busbars with various configurations via blocks of similar-sized material simplifies assembly. Furthermore, various configurations can be provided using similar molds because segments with various configurations can be set to similar sizes.

[0083] The foregoing description is exemplary in nature and not restrictive. It will likely be apparent to those skilled in the art that variations and modifications made to the disclosed examples do not necessarily depart from the spirit of this disclosure. Therefore, the scope of legal protection afforded to this disclosure can only be determined by studying the following claims.

[0084] According to the present invention, a busbar forming method includes: folding a sheet of material to form a plurality of creases, the creases dividing the sheet into a plurality of segments; identifying a desired size of a terminal receiving groove in the busbar; and, in response to the desired size, folding at least some of the segments relative to each other around at least some of the creases, according to a first process or a different second process.

[0085] According to one embodiment, each of the creases extends linearly along a direction transverse to the longitudinal axis of the sheet.

[0086] According to one embodiment, the creases are distributed along the longitudinal axis of the sheet, and each crease extends from a first transverse side of the sheet to the opposite second transverse side of the sheet.

[0087] According to one embodiment, the segments are all of equal size.

[0088] According to one embodiment, the crease includes at least partially perforating the sheet to form the crease.

[0089] According to one embodiment, both the first process and the second process include folding some of the same segments relative to each other around some of the same creases.

[0090] According to one embodiment, the creases are distributed such that the tool's punch can fold the sheet according to the first process, and the same punch can fold the sheet according to the second process.

[0091] According to one embodiment, the busbar provides a portion of the terminal receiving recess including a bottom and opposite sides, wherein at least one of the opposite sides includes some of the segments that are folded against each other.

[0092] According to one embodiment, a further feature of the invention is that, after the folding, a portion of the terminal receiving groove is provided to clamp the busbar to clamp a first number of battery terminal tabs when the desired opening size of the terminal receiving groove is a first large size, and the portion of the terminal receiving groove is provided to clamp the busbar to clamp a different second number of battery terminal tabs when the desired opening size of the terminal receiving groove is a different second large size.

[0093] According to one embodiment, the busbar extends along a longitudinal axis, and the clamping includes opposing axial sides of the portion of the busbar that provides the terminal receiving groove, which directly contacts the busbar.

[0094] According to one embodiment, the terminal receiving groove is a first terminal receiving groove, and the invention further includes: folding at least some of the segments relative to each other around some of the creases to provide a second terminal receiving groove in the busbar spaced apart from the first terminal receiving groove.

[0095] According to one embodiment, a further feature of the invention is that the first terminal recess and the second terminal recess are clamped to corresponding first and second sets of battery terminal tabs, and a portion of the busbar extending between the first and second terminal recesses is used as a spring to accommodate movement of the first and second sets of battery terminal tabs relative to each other during operation.

[0096] According to the present invention, a battery assembly is provided having: a busbar formed of a sheet of material having a terminal receiving groove; and a plurality of creases formed within the sheet, the plurality of creases dividing at least a portion of the sheet into a plurality of segments, wherein at least some of the segments are folded relative to each other around at least some of the creases to provide the terminal receiving groove in the busbar.

[0097] According to one embodiment, the terminal receiving groove is a first terminal receiving groove having a first size, wherein at least some of the segments are foldable relative to each other around at least some of the creases to provide a busbar having a second terminal receiving groove having a different second size.

[0098] According to one embodiment, the plurality of segments are of equal size.

[0099] According to one embodiment, at least some of the creases of the busbar that can be folded around some of the segments to provide a terminal receiving groove of the first size are the same as the creases of the busbar that can be folded around some of the segments to provide a terminal receiving groove of the second size.

[0100] According to one embodiment, each of the creases extends transversely to the longitudinal axis of the sheet, and the creases are distributed along the longitudinal axis such that the plurality of creases divide the sheet into a plurality of equal-sized segments.

[0101] According to one embodiment, the crease is the area of ​​at least partial perforation of the material sheet.

[0102] According to one embodiment, a further feature of the invention is at least one terminal of the battery sandwiched within the terminal receiving groove.

[0103] According to one embodiment, at least one terminal includes a first terminal tab extending a first distance from the outermost outer shell of a first battery cell, and also includes a second terminal tab extending a greater second distance from the outermost outer shell of a second battery cell, such that a portion of the first terminal tab outside the shell is longer than a portion of the second terminal tab outside the shell.

Claims

1. A busbar forming method comprising: folding a sheet of material to form a plurality of folds that divide the sheet into a plurality of segments; identifying a desired size of a desired terminal-receiving recess in a desired busbar; and in response to the desired size, folding at least some of the segments relative to one another about at least some of the folds to provide first and second busbars of different configurations according to a first folding procedure or a different second folding procedure, wherein the sheet with at least some of the segments folded according to the first folding procedure provides the first busbar with a terminal-receiving recess of a first size, wherein the sheet with at least some of the segments folded according to the second folding procedure provides the second busbar with a terminal-receiving recess of a second size different from the first size, wherein a portion of the busbar that provides the terminal-receiving recess includes a bottom and opposing sides, wherein at least one of the opposing sides includes some of the segments folded against one another to provide a thickness required to handle a current demand of a battery pack.

2. The method of claim 1, wherein the folds each extend linearly along a direction transverse to a longitudinal axis of the sheet.

3. The method of claim 2, wherein the folds are distributed along a longitudinal axis of the sheet, and each of the folds extends from a first lateral side of the sheet to an opposite second lateral side of the sheet.

4. The method of claim 1, wherein the segments are each equal in size.

5. The method of claim 1, wherein the folds include at least partially perforating the sheet to form the folds.

6. The method of claim 1, wherein the first folding procedure and the second folding procedure each include folding some of the same segments relative to one another about some of the same folds.

7. The method of claim 1, wherein the folds are distributed such that a male die of a tool can fold the sheet according to the first folding procedure, and the same male die can fold the sheet according to the second folding procedure.

8. The method of claim 1, further comprising: After the folding, clamping a portion of the first busbar that provides the terminal-receiving recess to crimp a first number of battery terminal tabs, and clamping the portion of the second busbar that provides the terminal-receiving recess to crimp a different second number of battery terminal tabs.

9. The method of claim 8, wherein the first busbar extends along a longitudinal axis, and the clamping includes directly contacting opposing axial side faces of the portion of the first busbar that provides the terminal-receiving recess.

10. The method of claim 1, wherein the terminal receiving groove in the first busbar is a first terminal receiving groove, and the method further comprises: Folding at least some of the segments relative to one another about some of the folds to provide a second terminal-receiving recess in the first busbar that is spaced apart from the first terminal-receiving recess.

10. The method of claim 9, wherein the first terminal-receiving recess is provided by a first one of the segments, and the second terminal-receiving recess is provided by a second one of the segments.

11. The method of claim 10, further comprising: clamping the first and second terminal recesses to respective first and second sets of battery terminal tabs and using a portion of the first busbar extending between the first and second terminal recesses as a spring to accommodate movement of the first and second sets of battery terminal tabs relative to one another during operation.

12. A battery assembly comprising: a busbar formed from a sheet of material, the busbar having a terminal receiving recess; and a plurality of creases formed within the sheet, the plurality of creases dividing at least a portion of the sheet into a plurality of segments, wherein at least some of the segments are folded relative to one another about at least some of the creases to provide the terminal receiving recess in the busbar, wherein the terminal receiving recess is a first terminal receiving recess of a first size folded according to a first folding process, wherein at least some of the segments are foldable relative to one another about at least some of the creases to provide a busbar having a terminal receiving recess of a second size different from the first size to provide a busbar having a first size terminal receiving recess and a busbar having a second size terminal receiving recess of different configurations, wherein a portion of the busbar providing the terminal receiving recess includes a bottom and opposing sides, wherein at least one of the opposing sides includes some of the segments folded against one another to provide a thickness required to handle current demands of a battery pack of the battery assembly.

13. The assembly of claim 12, wherein the plurality of segments are equal in size.

14. The assembly of claim 12, wherein at least some of the segments are foldable about to provide the busbar having the first size terminal receiving recess are the same as the creases about which at least some of the segments are foldable to provide the busbar having the second size terminal receiving recess.

15. The assembly of claim 12, wherein the creases each extend transverse to a longitudinal axis of the sheet and the creases are distributed along the longitudinal axis such that the plurality of creases divide the sheet into a plurality of equal sized segments.

16. The assembly of claim 12, wherein the creases are at least partially perforated regions of the sheet of material.

17. The assembly of claim 12, further comprising at least one terminal of a battery clamped within the terminal receiving recess.

18. The assembly of claim 17, wherein the at least one terminal includes a first terminal tab extending a first distance from an outermost housing of a first battery cell and further includes a second terminal tab extending a second, greater distance from an outermost housing of a second battery cell such that a portion of the first terminal tab outside of the housing is longer than a portion of the second terminal tab outside of the housing.

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