Electrical busbar and method of manufacturing the same

Abstract

The present invention generally provides a busbar for mechanically and electrically connecting components in a device. The busbar includes a plurality of conductors arranged to provide two opposing end portions and a middle portion, wherein each of the conductors has a plurality of middle extents extending across the middle portion. The middle portion includes: (A) an unfused section, wherein none of the middle extents of the conductor are fused together to form a single consolidated conductor; and (B) a fused section, wherein the fused section includes: (i) a partially cured region, wherein a majority of the middle extents of the conductor are fused together to form a partially cured region, which provides a single consolidated conductor; (ii) a fully cured region, wherein all of the middle extents of the conductor are fused together to form a fully cured region, which provides a single consolidated conductor; and (iii) an uncured region, wherein none of the middle extents of the conductor are fused together.

Description

Technical Field

[0001] The present disclosure relates to electrical connectors and, more particularly, to busbars used in electrical signal and power distribution systems, such as those found in automotive, military, marine, and aerospace applications. The busbars of the present invention have at least one fused section having a solidified region and one potentially unfused section, which enables the busbars to be formed into complex geometric configurations necessary in electrical signal and power distribution systems.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 897,962 filed on September 9, 2019, U.S. Provisional Patent Application No. 62 / 988,972 filed on March 13, 2020, and U.S. Provisional Patent Application No. 63 / 051,639 filed on July 14, 2020, all of which are incorporated herein by reference and made a part hereof. Background Art

[0004] The number of electronic devices, components and systems in the automotive, military, marine and aerospace sectors has increased dramatically over the past few decades and is expected to continue to increase in the future. The performance of devices, components and systems is an industry performance standard and a production and reliability requirement. For example, in the automotive sector, the number and complexity of electronic devices, components and systems in automobiles and other road and off-road vehicles (such as pickup trucks, commercial trucks, semi-trucks, motorcycles, all-terrain vehicles and sport utility vehicles (collectively referred to as "motor vehicles")) has increased dramatically. Electronic devices are used to improve performance, manage safety features, control emissions and provide creature comforts for occupants and users of motor vehicles. For motor vehicles, many electronic components and devices provide critical signal connections for vehicle airbags, batteries, battery power packs and advanced driver assistance systems (ADAS).

[0005] However, the operating environment of motor vehicles is challenging due to vibration, heat, and humidity, all of which can limit the performance, reliability, and service life of electronic devices and the connectors that mount them in the vehicle. The same challenges apply to the military, marine, and aerospace sectors. For example, high temperature, vibration, and humidity can all lead to premature wear and eventual failure of connectors and / or the devices themselves. In fact, loose connectors are one of the largest failure modes in motor vehicles, both in the assembly plant and in the field. Considering that the total warranty coverage for all global automakers and their direct suppliers is estimated to be between $50 billion and $150 billion annually, the automotive industry's large failure modes represent a significant financial cost.

[0006] Given these challenging electrical environments, a great deal of time, money, and effort has been expended to develop power distribution assemblies that meet all of the demands of these markets. Most conventional power distribution assemblies use custom busbars, which are expensive to manufacture and install. By using custom busbars, any modification to the power distribution system may require changing the configuration of one or more busbars. These modifications are very time-consuming to develop and further increase labor and installation costs. Once the configuration of these custom busbars is finalized and the busbars are manufactured, installers typically couple the busbars to the power source, power distribution components, or other equipment with a combination of conventional fasteners (e.g., elongated fasteners, washers, nuts, and / or studs). These conventional fasteners make installing the busbars in an application extremely difficult, as installers may need to wear protective equipment to protect themselves during this process. Finally, once conventional busbars are properly installed in an application, they are prone to high failure rates due to their complex geometry. Thus, there is an unmet need for an improved busbar that is boltless, suitable for modularization, and applicable to power distribution systems requiring complex geometries and that are commonly found in automotive, military, marine, and aerospace applications.

[0007] The description provided in the Background section should not be admitted to be prior art merely by virtue of being mentioned in or related to the Background section.The Background section may include information describing one or more aspects of the subject technology. Summary of the Invention

[0008] The present disclosure relates to a busbar having at least one fused, relatively stiff section and one unfused, flexible section, which enable the busbar to be formed into complex geometric shapes in a three-dimensional Cartesian X, Y, and Z coordinate system. The fused section of the busbar includes at least one area of ​​conductor that is partially or fully solidified, which increases the stiffness of the fused section of the busbar. The unfused section of the busbar includes unsolidified areas of conductor rather than partially or fully solidified areas of conductor, which allows the unfused section to be flexible and capable of bending in the in-plane XY directions or out-of-plane Z direction.

[0009] Thus, the busbar of the present invention can be installed in electrical signal and power distribution systems requiring complex geometric configurations, which are common in automotive, military, marine, and aerospace applications, which have industry performance standards and production and reliability requirements that the busbar of the present invention can meet due to its unique characteristics.

[0010] Other aspects and advantages of the present disclosure will become apparent upon consideration of the following detailed description and accompanying drawings, wherein like numerals represent like structures throughout the specification. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The accompanying drawings depict one or more embodiments according to the present teachings by way of example only and not limitation. In the accompanying drawings, like reference numerals designate the same or similar elements.

[0012] Figure 1A It is a conventional rigid busbar with an in-plane bending configuration;

[0013] Figure 1B A conventional flexible busbar having a configuration with multiple out-of-plane bends;

[0014] Figure 2A and Figure 2B shows the installation of a conventional busbar to a component in an application such as an automotive vehicle;

[0015] Figure 3A and Figure 3B shows the orientation of the three-dimensional X, Y, and Z Cartesian coordinate systems for straight and curved busbar configurations;

[0016] Figure 4 is a flow chart showing the steps for creating the busbar of the present invention;

[0017] Figure 5A A digital request from a customer for installing a plurality of busbars within a battery pack is shown, wherein specifications and requirements for the busbars are included in the customer's request;

[0018] Figure 6 is a flow chart showing steps for digitally designing a busbar;

[0019] Figure 7A shows a computer-generated model with a busbar layout that meets the customer's equipment specifications and requirements;

[0020] Figures 7B to 7F Shown include Figure 7A A perspective view of the busbars in the layout;

[0021] Figure 8 is a flow chart illustrating steps for selecting the material and configuration of conductors within a busbar based on a selected busbar design;

[0022] Figure 9A and Figure 9B shows a variety of different conductor configurations that can be selected during the busbar design process, where the width, height, layout, shape, orientation, and number of conductors are varied;

[0023] 10A to 10I shows a number of different conductor configurations that can be selected during the busbar design process, where the width, height, shape, orientation, and number of conductors are varied;

[0024] Figures 11A to 11F shows a variety of different conductor configurations that can be selected during the busbar design process, where the width, diameter, layout, shape, orientation, and number of conductors are varied;

[0025] 12A to 12D shows two different edge details that can be selected during busbar design, where Figure 12B yes Figure 12A An enlarged view of one conductor is shown in FIG. Figure 12D yes Figure 12C An enlarged view of a conductor shown in ;

[0026] Figure 13A and Figure 13B shows an intermediate busbar section having one uniform segment or multiple varying segments, where the segment design is based on the geometry of the bends contained within the busbar;

[0027] Figures 14A to 14G A plurality of different segments of a busbar are shown, wherein the design of the selected segment is based on the geometry of the bends contained within the busbar;

[0028] Figure 15 is a flow chart illustrating different methods that may be used to fuse selected segments of a busbar;

[0029] 16A to 16D shows an exemplary shape of a laser beam that may be used to fuse selected segments of a busbar;

[0030] Figures 16E to 16H shows an exemplary laser path that a laser may use to fuse selected segments of a busbar;

[0031] Figure 17A is a flow chart for determining a combined pattern of identified fused segments of a middle portion of a busbar;

[0032] Figure 17B is a flow chart for determining a combination pattern of an end portion of a bus bar;

[0033] 18A to 18R Exemplary waveform types that may be used to create a top fuse pattern and / or a bottom fuse pattern are shown;

[0034] Figure 19A shows a top fuse pattern comprising two exemplary waveforms configured to be disposed on a top surface of a fuse segment contained within a middle portion of a busbar;

[0035] Figure 19Bshows a bottom fuse pattern comprising two exemplary waveforms configured to be disposed on a bottom surface of a fuse segment contained within a middle portion of a busbar;

[0036] Figure 19C showing a combined fuse pattern comprising a top fuse pattern and a bottom fuse pattern, wherein the top fuse pattern and the bottom fuse pattern are arranged such that direct overlap between them is minimized;

[0037] Figure 20A showing a combined fused pattern having a first frequency and a first width designed to undergo out-of-plane bending;

[0038] Figure 20B showing a combined fused pattern having a second frequency and a first width designed to undergo in-plane bending;

[0039] Figure 20C showing a combined fused pattern having a third frequency and a second width;

[0040] Figure 20D showing a combined fused pattern having a fourth frequency and a third width;

[0041] Figure 21A shows the variation in frequency of waveforms contained within a combined fused pattern within a single fused segment of a busbar;

[0042] Figure 21B Another exemplary combined fused pattern is shown in which the frequency of the waveform varies within a single fused segment of the busbar;

[0043] Figure 22A showing a top fusion pattern configured to be disposed on a top surface of a fusion segment of an end portion of a busbar;

[0044] Figure 22B showing a bottom fusion pattern configured to be disposed on a bottom surface of a fusion segment of an end portion of a busbar;

[0045] Figure 22C shows a combined fuse pattern comprised of a top fuse pattern and a bottom fuse pattern, wherein the top fuse pattern and the bottom fuse pattern are arranged so as to minimize direct overlap between them;

[0046] Figure 22D and Figure 22E shows an alternative combined fusion pattern that may be provided on the fusion section of the end portion of the busbar;

[0047] 23A to 23D shows an exemplary embodiment of a combined fuse pattern that can be used with the middle portion of a busbar;

[0048] Figure 24A shows an exemplary busbar ready for digital testing to ensure it meets the customer's busbar specifications;

[0049] Figure 24B and Figure 24C shows a machine for digitally testing busbar designs to ensure they meet the customer's busbar specifications;

[0050] Figure 25 is a flow chart illustrating the manufacturing process of the busbar design of the present invention;

[0051] Figure 26 A laser welder is shown welding a middle portion of a busbar based on a combined fusion pattern associated with a selected design;

[0052] Figure 27 A laser welder is shown welding end portions of a busbar based on a combined fusion pattern associated with a selected design;

[0053] Figure 28 A laser welder is shown welding edge details associated with the selected design;

[0054] Figure 29 is a perspective view of a busbar of the present invention having a fused section with two combined surface patterns;

[0055] Figure 30 yes Figure 29 Top view of the busbar;

[0056] Figure 31 yes Figure 29 Bottom view of the busbar;

[0057] Figure 32 yes Figure 29 A first side view of a busbar;

[0058] Figure 33 yes Figure 29 A second side view of the busbar;

[0059] Figure 34 yes Figure 29 A first end view of a busbar;

[0060] Figure 35 yes Figure 29 A second end view of the busbar;

[0061] Figure 36 yes Figure 29 Top view of the busbar;

[0062] Figure 37 It is along Figure 36 The line 37-37 is intercepted Figure 36 sectional view of

[0063] Figure 38 yes Figure 37 , which shows a fused segment and an unfused segment including a partially solidified area and an unsolidified area;

[0064] Figure 39 yes Figure 38 , which shows a fused segment including a partially solidified area and an unsolidified area;

[0065] Figure 40 yes Figure 29 Top view of the busbar;

[0066] Figure 41 It is along Figure 40 The line 41-41 is intercepted Figure 40 sectional view of

[0067] Figure 42 yes Figure 41 An enlarged view of the embodiment of the present invention showing a fused section and an unfused section, wherein the fused section includes a fully solidified area and an unsolidified area;

[0068] Figure 43 yes Figure 42 , which shows a fused section including a fully solidified area and an unsolidified area;

[0069] Figure 44 yes Figure 29 Top view of the busbar;

[0070] Figure 45 It is along Figure 44 The line 45-45 is intercepted Figure 44 sectional view showing a fused section including a fully solidified region, a partially solidified region, and an unsolidified region;

[0071] Figure 46 yes Figure 29 Top view of the busbar;

[0072] Figure 47 It is along Figure 46 The line 47-47 intercepts Figure 46 sectional view showing a fused section including a fully solidified region and an unsolidified region;

[0073] Figure 48A It is a perspective view of a busbar insulation machine;

[0074] Figures 48B to 48D Shown Figure 48A Operation of a busbar insulation machine, wherein the insulation machine uses a cavity centering method to insulate the conductors of the busbar;

[0075] Figure 48E is used Figure 48A Insulation of machine-insulated busbars;

[0076] Figure 49A shows a laser welding machine forming an opening in a busbar, wherein the opening is designed to receive a conventional elongated coupler;

[0077] Figure 49B is an enlarged view of a bus bar having an opening formed in an end portion;

[0078] Figure 50A A laser welding machine is shown coupling an electrical connector assembly having an internal spring member to a bus bar;

[0079] Figure 50B is an enlarged view of a bus bar having an electrical connector assembly having an internal spring member coupled thereto;

[0080] Figure 51 is a flow chart illustrating options for delivering a busbar to a customer and installing the busbar;

[0081] Figure 52 is a first embodiment of a busbar bending machine that can be used during the manufacture of busbar prototypes and their testing;

[0082] Figure 53 is a second embodiment of a busbar bending machine that can be used during the manufacture of busbar prototypes and their testing;

[0083] Figure 54 is an embodiment of a busbar bending machine that can be used during mass production of busbars;

[0084] Figures 55A to 55B Shown Figure 54 How to bend the selected part of the busbar with the busbar bending machine;

[0085] Figure 56 is a perspective view of a busbar of the present invention having a fused section with two combined surface patterns, the busbar being in a bent configuration with the insulator removed;

[0086] Figure 57 yes Figure 56 A first end view of a busbar;

[0087] Figure 58 yes Figure 56 A second end view of the busbar;

[0088] Figure 59 yes Figure 56 A first side view of a busbar;

[0089] Figure 60 yes Figure 56 A second side view of the busbar;

[0090] Figure 61 yes Figure 56 Top view of the busbar;

[0091] Figure 62 yes Figure 56 Bottom view of the busbar;

[0092] Figure 63A is a perspective view of a housing of an electrical connector assembly having an internal spring assembly prior to coupling to a busbar;

[0093] Figure 63B yes Figure 63A A bottom view of the housing shown in ;

[0094] Figure 64 is a perspective view of a busbar of the present invention, wherein an insulator surrounds the busbar and the busbar has two electrical connector assemblies partially enclosed by a housing;

[0095] Figure 65 yes Figure 64 Top view of the busbar;

[0096] Figure 66 It is along Figure 65 The line 66-66 intercepts Figure 65 A cross-sectional view of a busbar of the present invention, showing partially solidified areas and unsolidified areas of a fused section of the busbar;

[0097] Figure 67 shows two end portion configurations of a busbar that may be used when joining two busbars together in a "weaving" configuration;

[0098] Figure 68 shows two end portion configurations of a busbar that may be used when joining two busbars together in an "offset stack" configuration;

[0099] Figures 69 to 70 A laser welding machine is shown welding the end portions of two busbars at a joining area;

[0100] Figure 71 shows two busbars joined together at a joining region, wherein each busbar includes both fused and unfused sections;

[0101] Figure 72 Shown Figure 54 A top view of a busbar shown in FIG, wherein the busbars have been joined together using a "densification" weld and a "butt" weld;

[0102] Figure 73 It is a perspective view of a resistance welding machine;

[0103] Figure 74 is the bus and Figure 73 a cross-sectional view of a range of resistance welding machines, wherein the welding machine is set to a prototyping mode;

[0104] Figure 75 is the bus and Figure 73 A cross-sectional view of a range of resistance welding machines, wherein the welding machine is configured for mass production manufacturing mode;

[0105] Figures 76 to 78 Is installed when the machine is in batch production mode Figure 73 An exemplary embodiment of an electrode roller in a welding machine;

[0106] Figure 79 is a perspective view of a second embodiment of a busbar of the present invention wherein an insulator extends between opposing electrical connector assemblies;

[0107] Figure 80 is a perspective view of a third embodiment of a busbar of the present invention, wherein an insulator extends between opposing electrical connector assemblies;

[0108] Figure 81 is a perspective view of a fourth embodiment of a busbar of the present invention, wherein an insulator extends between opposing electrical connector assemblies;

[0109] Figure 82 is a perspective view of a fifth embodiment of a busbar of the present invention, wherein an insulator extends between opposing bolt and nut connectors;

[0110] Figure 83 is a perspective view of a battery pack mounted within a skateboard of a vehicle, wherein the battery pack includes a plurality of busbars of the present invention electrically and mechanically connected to modules within the battery pack; and

[0111] Figure 84 is a perspective view of a vehicle having a battery pack including a plurality of busbars of the present invention electrically and mechanically connected to modules within the battery pack. DETAILED DESCRIPTION

[0112] In the following detailed description, numerous specific details are set forth by way of example in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to one of ordinary skill in the art that the present teachings can be practiced without such details. In other instances, well-known methods, procedures, components, and / or circuits have been described at a relatively high level without detailed description in order to avoid unnecessarily obscuring aspects of the present teachings.

[0113] Although the present disclosure includes many different forms of embodiments, specific embodiments are shown in the accompanying drawings and will be described in detail herein, it is understood that the present disclosure should be considered as an illustration of the principles of the disclosed method and system, and is not intended to limit the broad aspects of the disclosed concept to the embodiments shown. As will be realized, the disclosed method and system are capable of other and different configurations, and several details can be modified without departing from the scope of the disclosed method and system. For example, one or more embodiments (partial or complete) in the following embodiments can be combined with the disclosed method and system in a consistent manner. Therefore, one or more steps in the flowchart or components in the figure can be selectively omitted and / or combined with the disclosed method and system in a consistent manner. In addition, the steps included in the flowchart can be performed in different orders. In other words, it is not necessary to strictly follow the order of the steps described below. On the contrary, the steps can be performed in an unordered manner. Therefore, the accompanying drawings, flowcharts and specific embodiments should be considered to be illustrative in nature, rather than restrictive or limiting.

[0114] 1) Definition

[0115] The following terms are used throughout this specification and are defined as follows: The term "partially solidified region" is the region of the fused section in the middle portion of the busbar, where the region extends from the lowermost conductor in the fused section to the uppermost conductor in the fused section. For example, in Figure 39 , a region 1660 of the busbar 1000 extending between the top surface 1000a and the bottom surface 1000b has undergone a partial penetration welding process.

[0116] The term "partially solidified region" refers to an area of ​​a busbar that has undergone a partial penetration welding process. This process combines or fuses some (but not all) of the intermediate area of ​​conductors contained within the partially solidified region to form the partially solidified region, which provides a single, consolidated conductor. Figure 38 、 Figure 39 and Figure 4516. An example of a partially cured region 1650 is shown in FIG. In partially cured region 1650, a substantial amount (e.g., approximately 70%) of the conductors 1090 within partially cured region 1660 are combined into a single consolidated conductor, and a minimal amount (e.g., approximately 30%) of the conductors within partially cured region 1660 and outside of partially cured region 1650 remain as individual conductors 1090, meaning they are not combined or fused into a single combined conductor.

[0117] The term "uncured region" means an area of ​​the busbar that has not yet undergone a welding process to combine or fuse any conductors contained within that area of ​​the busbar. Thus, all conductors located within the uncured region remain as separate conductors. For example, Figure 39 An uncured region 1670 is shown adjacent to and between two partially cured regions 1650 within the fused section 1220 of the middle portion 1200 of the busbar 1000 of the present invention.

[0118] The term "fully solidified region" means a region of the busbar that has undergone a full penetration welding process to combine or fuse all of the conductors contained within that region of the busbar into a single consolidated conductor. For example, Figure 43 A fully cured region 1690 is shown peeled away from the uncured region 1670 within the fused section 1220 of the middle portion 1200 of the busbar 1000 of the present invention.

[0119] The term "fused section" is a region of a busbar that contains at least one partially solidified region, a fully solidified region, or both. The fused section may also include unsolidified regions. For example, Figure 39 Uncured areas 1670 and partially cured areas 1650 are shown, and Figure 43 An uncured region 1670 is shown surrounding a fully cured region 1690, both within the fused section 1220 of the middle portion 1200 of the busbar 1000 of the present invention.

[0120] The term "unfused section" is the area of ​​the busbar that does not contain partially solidified areas or fully solidified areas. Therefore, the unfused section only contains unsolidified areas. For example, Figure 38 and Figure 42 An unsolidified region 1670 within the unfused section 1520 of the middle portion 1200 of the busbar 1000 of the present invention is shown.

[0121] The term "in-plane" refers to the X and Y directions in a three-dimensional Cartesian X, Y, and Z coordinate system, such as Figures 3A to 3B The term "in-plane bend" refers to a type of bend in a busbar that is oriented in the XY plane and is oriented transversely, typically perpendicular to the width of the busbar. Figure 1AThe busbar 10 is shown with two exemplary in-plane bends 1750 in the XY plane, formed within the fused section 1220 of the middle portion 1200 of the busbar 1000 of the present invention.

[0122] The term "out-of-plane" refers to the Z direction in the three-dimensional Cartesian X, Y, and Z coordinate system, as shown in Figure 3. The term "out-of-plane bend" is a type of bend in a busbar that is oriented in the Z direction and is perpendicular to the XY plane. Figure 1B A busbar 20 is shown having two out-of-plane bends 1760 in the Z direction.

[0123] The term "high power" shall mean: (i) any voltage between 20 volts and 600 volts, regardless of the current; or (ii) any current greater than or equal to 80 amperes, regardless of the voltage.

[0124] The term "high current" shall mean current greater than or equal to 80 amperes, regardless of voltage.

[0125] The term "high voltage" shall refer to voltages between 20 volts and 600 volts, regardless of current.

[0126] 2) Overview of conventional bus

[0127] Figure 1A A conventional rigid busbar 10 is shown in FIG. Figure 1B A conventional flexible busbar 20 is shown in , where both conventional busbars 10, 20 are subject to a number of limitations. For example, the conventional rigid busbar 10: (i) has a high manufacturing cost; (ii) cannot effectively account for manufacturing tolerances; and (iii) cannot properly expand or contract during battery charge and discharge cycles. While the conventional flexible busbar 20 solves some of the problems associated with the conventional rigid busbar 10, the flexible busbar 20 has its own significant limitations. For example, the conventional flexible busbar 20: (i) cannot be easily connected to other objects; (ii) can be expensive to manufacture; and (iii) cannot maintain in-plane bending of the busbar without creating large gaps (e.g., delamination) between the conductors contained within the flexible busbar 20, which in turn reduces the current within the busbar 20. In order to achieve an in-plane bending configuration using the flexible busbar 20, the flexible busbar 20 is folded 22 (see ) in a manner that causes a first extent of the busbar 20 to overlap with a second extent of the busbar 20. Figure 1B). This folded configuration increases the required height of the busbar 20, and the geometry of the fold limits the current that can flow through the busbar 20. Additionally, even out-of-plane bending can cause the resistance of the busbar 20 to increase, which can lead to hot spots in the insulator and even cause the busbar 20 to fail. Furthermore, the edges of the flexible busbar 20 can tear or wear away the insulator; thereby causing the entire busbar 20 to fail. To address some of these issues, companies have attempted to connect separate and different flexible busbars with separate and different rigid busbars. Piecing these two separate and different types of busbars together is expensive, time consuming, prone to extremely high failure rates in their joining areas, and a large amount of material is wasted in attempting to form these busbars.

[0128] In addition to these problems, conventional busbars 10, 20 connected to components using conventional connectors 24 also have many problems. For example, conventional busbars 10, 20 and connectors 24 have the following problems: (i) installation is time-consuming; (ii) a high level of skill and dexterity is required to perform the installation; (iii) a number of safety issues; (iv) if the conventional connector is dropped or misplaced within the battery pack during the installation process, the entire battery pack may need to be disassembled; (v) the failure rate is high; (vi) multiple people are required to confirm that a single installation has been performed correctly; and (vii) a large amount of space and weight are required. Figure 2A and Figure 2B As shown, there are a number of safety issues when installer "I" is working on an open battery pack. To mitigate some of these issues, installer "I" wears thick protective gloves 26 and uses custom designed tools 28. Custom designed tools 28 are expensive, and the thick protective gloves 26 require installer "I" to have a high level of skill and dexterity to ensure that the conventional connector 24 is not accidentally dropped into the battery pack or the surrounding environment. If such an accident occurs, the installation process needs to be stopped and the entire battery pack must be disassembled in order to find the misplaced conventional connector 24. Even assuming that the installation goes as planned, another person (other than installer "I") is usually required to check the torque of the conventional connector 24 and apply a mark or mark to indicate that the necessary checks have been performed. Because the confirmation of the connection is done by hand, the manufacturing company may not have a digital record showing when the conventional connector was connected and whether it was connected correctly.

[0129] 3) Design and manufacture of the busbar of the present invention

[0130] The inventive busbar 1000 disclosed herein overcomes many of the limitations disclosed above while meeting automotive, military, marine, and aerospace performance, production, and reliability requirements. Specifically, the busbar 1000 includes a plurality of conductors 1090 arranged to provide two opposing end portions 1700 and a middle portion 1200, wherein each of the conductors 1090 has a plurality of intermediate extents that traverse or span the middle portion 1200. The middle portion 1200 includes: (i) a first or fused section 1220; and (ii) a second or unfused section 1520. First, integrally forming the fused section 1220 and the unfused section 1520 into a single busbar 1000 allows the busbar 1000 to combine the best features of a conventional rigid busbar 10 and a conventional flexible busbar 20 into a single unit while limiting the negative features associated with these conventional busbars 10, 20. For example, the unfused segments 1520 are flexible, which allows the busbar 1000 to: (i) accommodate manufacturing tolerances; (ii) expand and contract during thermal expansion and contraction events (such as battery charge and battery discharge cycles); and (iii) help absorb vibrations caused by the environment in which the busbar 1000 is installed (e.g., under the hood of a vehicle) rather than transmitting these vibrations into the connector. Additionally, the fused segments 1220 of the busbar 1000 are more rigid, which allows the busbar 1000 to flex accurately both out-of-plane and in-plane, and in particular, to maintain in-plane bending over time without delamination of the conductors 1090 contained within the busbar 1000, thereby reducing current flow. This attribute of the busbar 1000 is beneficial because: (i) it reduces the required overall height of the busbar 1000; and (ii) it does not restrict current flow through the fused segments, which in turn allows the busbar 1000 to carry more current without creating hot spots or causing a significant temperature increase. In addition, the edges of busbar 1000 can be modified to reduce the likelihood that the conductors contained within busbar 1000 will tear or wear away surrounding insulation. Furthermore, by integrally forming fused section 1220 and unfused section 1520 as a single busbar 1000, the high cost, significant failure rate, and material waste associated with conventional busbars that are pieced together are eliminated. Finally, the inclusion of fused section 1220 and unfused section 1520 allows busbar 1000 to: (i) be formed without the need for custom molds; and (ii) be shipped to customers in a substantially flat configuration, which reduces packaging, handling, and shipping costs, and also reduces the likelihood that busbar 1000 will be damaged during shipping or while being handled prior to installation in a component, device, or vehicle.

[0131] The busbar 1000 of the present invention can use a conventional connector 24 or a boltless connector system 2000. The boltless connector system 2000 does not use bolts, screws, fasteners, etc. to connect at least a certain range of the busbar 1000 between: (i) between power sources (e.g., an alternator or battery); (ii) between a power source and a power distribution / control component; or (iii) between a power source and a device (e.g., a radiator fan, heated seats, power distribution components, or other current consuming components). This boltless connector system 2000 and its features are described in at least PCT / US20 / 14484, which is incorporated by reference, and overcomes many of the limitations associated with conventional busbar connectors 24. For example, the boltless connector system 2000 requires only one person to connect the male connector assembly 2200 into the female connector assembly 2600, hear an audible signal (e.g., a "click"), pull the connector assemblies 2200, 2600 to ensure they are properly coupled together, and read the range of the system (push, click, drag, read - "PCTR" compliant). In other words, the bus 1000 can be coupled to another component or device without the use of separate tools, which reduces safety concerns, reduces assembly and handling time, and does not require the high level of skill and dexterity required to install conventional bus connectors 24. Manufacturing time remains consistent because there are no loose parts that can become lost within the battery pack or surrounding environment. Additionally, labor costs are better managed and reduced because the handling and installation of the bus 1000: (i) requires only one person, which takes less time to install the bus 1000, and (ii) requires less space (e.g., a conventional connector height (D1, as shown in FIG. 2 ). Figure 2B shown) from about 40 mm to 16 mm); and (iii) easier because the busbar 1000 is about 50% lighter than conventional busbars 10, 20.

[0132] In addition to its use within vehicle battery packs, bus 1000 may also be used to provide mechanical and electrical connections in other electrical systems found in: aircraft; motor vehicles; military vehicles (e.g., tanks, troop carriers, heavy trucks, and cavalry carriers); buses; locomotives; tractors; boats; submarines; battery packs; voltage systems exceeding 24 volts; high power applications; high current applications; high voltage applications; or another application where bus 1000 is critical to meeting industry standards and production requirements.

[0133] A. Design of the Busbar of the Invention

[0134] The design and manufacture of Busbar 1000 is a combination of Figure 4 The multi-step process 50 is described at a high level. Figure 4As shown, the multi-step process 50 begins by receiving specifications from the customer in step 52. These customer specifications can include a variety of different requirements, including but not limited to: (i) current carrying capacity; (ii) geometric constraints; (iii) material and / or chemical constraints; (iv) manufacturing repeatability; (v) durability; (vi) compliance with standards-setting bodies; (vii) environmental constraints; (viii) manufacturing requirements; and (ix) other requirements. These customer specifications can be sent to the busbar designer in any manner and can take any form, including datasheets and CAD models. For example, Figure 5 shows an example of a portion of the customer specifications received in step 52. Specifically, Figure 5 shows a digital 3D CAD model of a battery pack 54 including eight battery modules 56a-56h. The customer requires that the busbar 1000 be capable of: (i) mechanically and electrically coupling the external battery pack connector 58 to the battery modules 56a-56h; and (ii) coupling the battery modules 56a-56h to each other. Once the customer specifications are received, the bus designer may adopt the specifications and proceed to step 64 of the multi-step process 50 .

[0135] The next step in the multi-step process 50 for designing and manufacturing busbar 1000 is step 64 (see Figure 6 ), which requires digitally designing engineering bus models 100 that meet the customer specifications received in step 52. In designing these engineering bus models 100, it may be necessary to understand how power will be routed within the customer's application, product, component, or device. Specifically, it may be necessary to understand how the bus will route power within the application, product, component, or device so that the bus designer can create an engineering bus model 100 that: (i) meets the customer's specifications; (ii) minimizes the length and weight of the bus; (iii) allows for proper electrical and mechanical connections; (iv) minimizes the required height of the bus; and (v) minimizes overlapping busses. To gain this understanding, the designer can create a model of the bus layout 70 within the application, product, component, or device (step 66). Figure 7A An example of a model of the busbar layout 70 is shown in FIG. Figure 7A Eight different non-engineered busbar models 68a-68h are shown that may be used within the customer's application, product, component, or device shown in FIG. 5 . Figures 7B to 7F Individual views of several of these non-engineering busbar models 68a-68e are shown. While these non-engineering models 68a-68h are not suitable for manufacturing purposes, they provide the general overall geometry of the busbar. The next steps described herein will be directed toward converting these non-engineering models 68a-68h into engineering models 100 that can be manufactured.

[0136] return Figure 6 The next step in digitally designing the engineering busbar model 100 is to select the material and configuration of the conductors 90 to be included in the busbar model 100 (step 74). Figure 8 The process of step 74 is described in more detail in FIG. With the non-engineering models 68a-68h, the bus designer can select the materials to be used in the engineering bus model 100 (step 78). Figure 8 As shown, the busbar designer may choose to manufacture the busbar pattern 100 from a single material in step 80. Such materials may include, but are not limited to, stainless steel, nickel, aluminum, silver, gold, copper, steel, zinc, brass, bronze, iron, platinum, lead, molybdenum, calcium, tungsten, lithium, tin, combinations of the listed materials, or other similar metals. For example, the busbar designer may choose to use C10200 copper alloy in conjunction with the engineering busbar patterns 68a, 68b. This copper alloy has an electrical conductivity exceeding 80% of the IACS (International Annealed Copper Standard, an empirically derived standard for the electrical conductivity of commercial copper). This copper alloy is reported to have an elastic modulus (Young's modulus) of approximately 115-125 gigapascals (GPa) at room temperature according to ASTM B747, and a coefficient of thermal expansion (CTE) of 17.6 ppm / °C (20-300°C) and 17.0 ppm / °C (20-200°C).

[0137] Alternatively, the busbar designer may choose to use multiple materials in step 82. If the busbar designer makes this choice, the designer must then select a configuration of the materials in step 84. For example, the busbar designer may choose to alternate materials within the busbar pattern 100 or may interweave two different materials within the busbar pattern 100. More specifically, the pattern 100 may include alternating layers of copper and aluminum, or may include plated conductors ( Figure 9A ) 90, the plated conductor includes an aluminum core and a copper plating layer. It should be understood that the above materials and material configurations are merely examples, and the present disclosure also contemplates other similar materials and configurations.

[0138] Once the material and its configuration are selected in step 78, the busbar design can select the configuration of the conductors 90 in step 88. Step 88 consists of several sub-steps, such as Figure 8 One of the sub-steps included in step 88 requires selecting an overall configuration of conductor 90 in step 92. Non-limiting examples of configurations that the designer may select include: (i) a vertical stack or a laminated stack (see Figure 9B ); (ii) woven, knitted or braided patterns (see FIG. 10C to FIG. 10I ); or (iii) other configurations (see Figures 11A to 11F). Additionally, selecting the overall configuration of the conductors 90 in step 92 includes selecting the number of conductors 90 to be included within the busbar pattern 100. In making this selection, the busbar designer may maintain the number of conductors 90 consistent throughout the busbar pattern 100, or may vary the number of conductors 90 included within the pattern 100. For example, the designer may choose to increase the number of conductors 90 near the end portions, or may decrease the number of conductors 90 within the middle portion of the busbar pattern 100. It should be understood that the exemplary non-engineering busbar patterns 68a, 68b may utilize a laminate stack consisting of ten conductors 90, wherein the number of conductors 90 does not vary over the length of the busbar pattern 100.

[0139] Another sub-step in step 88 requires selecting a shape for each conductor 90 within the busbar model 100 in step 94. Exemplary shapes include, but are not limited to, rectangular prisms or rectangular rods (see Figure 9B ), "U-shaped" plate (see Figure 10C ), a cylinder, a pentagonal prism, a hexagonal prism, an octagonal prism, a pyramid, a tetrahedron, or any other similar shape. In making this choice, the busbar designer can maintain the shape of the conductor 90 consistent throughout the busbar pattern 100, or can vary the shape of the conductor 90 included within the pattern 100. It may be desirable to vary the shape of the conductor 90 to increase mechanical strength or current capacity within certain sections of the busbar pattern 100. It should be understood that the conductor 90 included within the exemplary non-engineering busbar patterns 68a, 68b can be in the shape of a rectangular prism or a rectangular rod.

[0140] Additionally, selecting the shape of each conductor 90 in step 94 includes selecting the thickness of the conductor 90 contained within the busbar pattern 100. In making this selection, the busbar designer can maintain a consistent thickness of the conductor 90 throughout the busbar pattern 100, or can vary the thickness of the conductor 90 contained within the pattern 100. It may be desirable to vary the thickness of the conductor 90 to increase mechanical strength or current capacity within certain sections of the busbar pattern 100. Additionally, selecting the shape of each conductor 90 in step 94 includes selecting whether the conductor 90 contained within the busbar pattern 100 has a solid, partially solid, or hollow configuration. It should be understood that the conductor 90 contained within the exemplary non-engineering busbar patterns 68a, 68b can be solid, have a substantially constant thickness of 0.01 inches or 0.254 mm, have a length of 13.5 inches or 344 mm, and have a width of 0.78 inches or 20 mm.

[0141] Another sub-step in step 88 requires selecting the arrangement of conductors 90 within busbar model 100 in step 96. For example, the busbar designer may desire Figure 11E The particular circular configuration shown in Figure 11FThe last sub-step in step 88 is to select the edge details of the busbar model 100, as shown in step 98. For example, the designer may select FIG. 12A to FIG. 12B coined edge detail 104 as shown, or as FIG. 12C to FIG. 12D The circular weld pattern 106 is shown. It should be understood that the Figures 16F to 16H Any weld pattern shown in Figure 16E 106, 832. In making this selection, the busbar designer can keep the edge detail consistent throughout the busbar model 100, or can vary the edge detail included within the model 100. Varying the edge detail may facilitate bending of the busbar. For example, the designer may choose to use a combination of a weld pattern and a coined edge detail in the areas that will be bent, while only using the weld pattern in the other fused sections 220 of the busbar 100. It will be appreciated that the exemplary non-engineering busbar models 68a, 68b may use the edge detail illustrated by the circular weld pattern 106, 832.

[0142] When making the above selections, the designer may wish to ensure that: (i) the thickness of the conductor 90 is greater than 0.01 mm; (ii) the width of the conductor 90 is greater than 1 mm, and preferably between 10 mm and 25 mm; and (iii) there are more than two conductors 90 in the busbar, and preferably between 5 and 35 conductors 90. It should be understood that the above configurations, shapes, arrangements, and edge details are merely examples of possible choices, and that the present disclosure contemplates other similar configurations, shapes, arrangements, and edge details.

[0143] return Figure 6Once the material and configuration of the conductor 90 are selected in step 74, the busbar designer may identify the segments 220 in the middle portion 200 of the busbar 100 that are to be fused in step 110. Furthermore, by identifying the segments 220 in the middle portion 200 of the busbar 100 that are to be fused, the design also identifies the segments 520 in the busbar 100 that will not be fused. The designer will identify these segments 220 based on a number of factors, which may include: (i) the width of the busbar; (ii) the geometry of the bends contained within the busbar (e.g., in-plane bends 750 or out-of-plane bends 760); (iii) the number of conductors 90 contained; (iv) the thickness of the conductors 90; (v) the material properties of the conductors 90; (vi) the type or method of fusing; (vii) the commercial throughput of the machine performing the fusing; (viii) the total number of bends contained within the busbar; (ix) the spacing of the bends within the busbar; (x) other customer specifications; and (xi) other factors that will be apparent to one skilled in the art based on the above list of factors. Once the designer has analyzed some or all of the above factors, the designer can determine whether the middle portion 200 of the busbar model 100 should: (i) contain no fused segments 220 and only unfused segments 520; (ii) contain only one fused segment 220 extending between the two end portions 720 (see Figure 13A ) 222; or (iii) comprising a plurality of fused segments 220 (see Figure 13B ) 224. It should be understood that the fused section 220 is less flexible, more rigid, or harder than the unfused section 520.

[0144] The following are non-limiting examples of how fused segments 220 and unfused segments 520 may be selected and arranged within the busbar 100. In one example, the middle portion 200 may not include any fused segments 220 if: (i) the busbar 100 does not include any bends (see 68e); (ii) the bends included within the busbar 100 are out-of-plane bends 760 and have wide bend radii; or (iii) the designer determines that the busbar 100 does not need to include such segments. If the busbar designer determines that the busbar model 100 does not need to include any fused segments 220, the designer may proceed to the next step in the process. In a second example, the middle portion 200 may include only one fused segment 220 (e.g., Figure 13A20 ). The busbar 100 may be configured to have a single bend (e.g., as shown): (i) the busbar 100 includes only a single bend; (ii) the overall length of the busbar 100 is short (e.g., less than 8 inches) and the busbar 100 includes multiple bends; (iii) the overall length of the busbar 100 is not long (e.g., greater than 3 feet) and the busbar 100 includes only a single bend type (e.g., in-plane bend 750 or out-of-plane bend 760); or (iv) the designer determines that the busbar 100 only needs to include this single segment. One of the main reasons a designer might choose to use only a single fused segment 220 is that the difference in manufacturing time between using a single segment and multiple segments does not justify attempting to create multiple segments. Once it is determined that the busbar 100 should include one fused segment 220, the busbar designer must then determine the general characteristics of the segment 220. These general characteristics are based on the designer's analysis of some or all of the factors listed above.

[0145] Alternatively, if the busbar model 100 includes a non-bending range, out-of-plane bending 760, and in-plane bending 750, the designer may choose to use multiple fused segments 220. This may be desirable because the designer can vary the properties of each fused segment 220, which in turn provides the necessary welds for certain ranges of the busbar 100, but without requiring the entire busbar 100 to be welded at a frequency suitable only for the bends requiring the greatest force. Varying the properties allows for improved manufacturing time and eliminates the possibility of over-welding the busbar 100. Once it is determined that the busbar should include multiple segments 220 within the busbar, the busbar designer must determine the location and general properties of each segment 220 to be included within the busbar 100.

[0146] FIG. 14A to FIG. 14B Various examples 250, 254, 258, 262, 266, 270, 274 of busbar models 100 including multiple fused segments 220 are shown in FIG. For example, a designer may choose to use Figure 14AThe busbar design 250 shown in the figure and labeled Design 1 (along the right side of the figure) is used to construct the busbar 100 shown in the non-engineered busbar model 68b. This is because the middle portion 200 of the non-engineered busbar model 68b contains only two similar in-plane bends 750, and therefore the two fused segments 220, 251a-251b can have the same general properties 250a. These general properties 250a include: (i) stiffness; (ii) ductility; (iii) flexibility; (iv) flexural modulus; (v) resilience; or (vi) other similar properties. In addition, the non-engineered busbar model 68b has an unbent region 252 located between the two fused segments 220. The designer may choose to use an unfused segment 520 for this unbent region 252 of the busbar 100. Thus, this exemplary layout of the non-engineered busbar pattern 68b will include: (i) two end portions 700, 702a, 702b; and (ii) a middle portion 200. The middle portion 200 includes: (i) two fused segments 220, 251a-251b, the two fused segments having the same general properties 250a; and (ii) an unfused segment 520 having general properties 250b contained within the segment 520, the general properties being associated with the respective conductors 90 in their particular arrangement. This exemplary configuration of fused segments 220 and unfused segments 520 contained within the non-engineered busbar pattern 68b will allow the busbar 100 to achieve the in-plane bending 750 shown with respect to the pattern 68b, and will allow the non-bending range 252 to bend, expand, contract, absorb vibration, or move as required by the busbar 100 during operation of the customer application, product, component, or equipment shown in FIG5 . As discussed above, this provides significant advantages over conventional busbars 10 , 20 .

[0147] In another example, the designer may choose to use Figure 14A and the busbar design 254 shown in labeled Design 2 to construct the busbar 100 shown in the non-engineering busbar model 68a. This is because the middle portion 200 of the non-engineering busbar model 68a includes: (i) two similar in-plane bends 750, and therefore the two fused segments 220, 253a-253b can have the same first set of general characteristics 254a; and (ii) two similar out-of-plane bends 760, and therefore the two fused segments 220, 253c-253d can have the same second set of general characteristics 254b. However, as Figure 14AAs shown in labeled Design 2, the first set of general characteristics 254a differs from the second set of general characteristics 254b. These first and second sets of general characteristics 254a, 254b differ because the bends are different. For example, welds included in the first set of general characteristics 254a need to be made more frequently than welds included in the second set of general characteristics 254b due to the fact that in-plane bends 750 exert greater forces on conductor 90 than out-of-plane bends 760. Additionally, the non-engineered busbar model 68a has a non-bending region 256 located between the innermost fused segments 220, 253a. The designer may choose to use unfused segments 520 for this non-bending region 256 of the busbar 100.

[0148] Thus, the above exemplary layout of the non-engineered busbar model 68a would include: (i) two end portions 700, 702a, 702b; and (ii) a middle portion 200. The middle portion 200 includes: (i) two fused segments 220, 253a-253b, each of which has a first set of general characteristics 254a; (ii) two fused segments 220, 253c-253d, each of which has a second set of general characteristics 254b; and (iii) one unfused segment 520 having general characteristics 254c contained within the segment 520, the general characteristics being associated with each conductor 90 in its particular arrangement. This exemplary configuration of fused segments 220 and unfused segments 520 contained within the non-engineered busbar pattern 68a will allow the busbar 100 to achieve the in-plane bending 750 shown with respect to the pattern 68a, and will allow the non-bending range 256 to flex, expand, contract, absorb vibration, or move as required by the busbar 100 during operation of the customer application, product, component, or equipment shown in FIG5 . As described above, this provides significant advantages over conventional busbars 10, 20.

[0149] Alternatively, the designer may choose to use Figure 14A and the busbar design 258 shown in the labeled Design 3 to construct the busbar 100 shown in the non-engineered busbar model 68a. This is because the middle portion 200 of the non-engineered busbar model 68a contains: (i) four bends, and therefore the fused segments 220, 259a-259d can have a first set of general characteristics 258a; and (ii) three ranges located between the bends that can account for the forces radiating from the four bends, and therefore the fused segments 220, 259e-259j can have a second set of general characteristics 258b. Figure 14AAs shown in the labeled design 2, the first set of general characteristics 258a is different from the second set of general characteristics 258b. These first set of general characteristics 258a and the second set of general characteristics 258b are different because the forces experienced by these areas are different. In addition, the non-engineered busbar pattern 68a has a non-bending range 260 located between the innermost fused sections 220, 259b. The designer may choose to use the unfused section 520 for this non-bending range 256 of the busbar 100. Therefore, the above example layout of the non-engineered busbar pattern 68a would include: (i) two end sections 720a, 720b; and (ii) the middle section 200. The intermediate portion 200 includes: (i) four fused segments 220, 259a-259d, each of which has a first set of general characteristics 258a; (ii) three fused segments 220, 259e-259j, each of which has a second set of general characteristics 258b; and (iii) one unfused segment 520, which has general characteristics 258c contained within the segment 520, which are associated with each conductor 90 in its particular arrangement.

[0150] In a second alternative, the designer may choose to use Figure 14B and busbar design 262 shown in labeled Design 4 to construct the busbar 100 shown in the non-engineered busbar model 68a. This is because the middle portion 200 of the non-engineered busbar model 68a includes four bends, and therefore these fused segments 220, 263 can have a first set of general characteristics 262a. In addition, the non-engineered busbar model 68a has non-bend regions 264a-264e surrounding the fused segments 220, 263, which have a second set of general characteristics 262b. The designer may choose to use unfused segments 520 for these non-bend regions 264a-264e of the busbar 100. Therefore, the above example layout of the non-engineered busbar model 68a would include: (i) two end portions 702a, 702b; and (ii) the middle portion 200. The intermediate portion 200 includes: (i) four fused segments 220, 264a, each of which has a first set of general characteristics 258a; and (ii) five unfused segments 520, each of which has a general characteristic 264c contained within the segment 520, the general characteristic being associated with each conductor 90 in its particular arrangement.

[0151] In a third alternative, the designer may choose to use Figure 14Aand busbar design 250 shown in labeled Design 1 to construct the busbar 100 shown in the non-engineered busbar model 68a. In this alternative example, the designer can use the weld frequencies required for in-plane bends 750 for all four bend regions. This can be beneficial because variations in manufacturing time may not be sufficient to change the general characteristics of each type of bend. Finally, the busbar layouts 266, 270, and 274 can include multiple fused segments 220 and multiple unfused segments 520. Specifically, the busbar design 266 can be used to create Figure 79 Although the busbar design 270 can be used to create Figure 80 busbar 5000 is shown in FIG, but busbar design 274 can be used to create Figure 81 In general, it should be understood that the middle portion 200 can include any number (e.g., 0-1000) of fused regions 220 and any number (e.g., 0-1000) of unfused regions 520. For example, the middle portion 200 can include only a single fused region 220.

[0152] return Figure 6 Once the fused segments 220 of the middle portion 200 of the busbar 100 are identified in step 110 , the busbar designer may select a method for fusing the identified segments 220 within the middle portion 200 and the end portions 700 in step 114 . Figure 15 Examples of possible fusion methods are shown in . Specifically, these fusion methods include: (i) laser welding 800; (ii) resistance welding 900; (iii) cold forming 910; (iv) arc welding 920; (v) electron beam welding 930; (vi) orbital welding 940; (vii) ultrasonic welding 950; (viii) friction welding 960; (ix) any combination of the above methods 970; or (x) other known methods for fusing metal 980. In making this selection, the designer may consider some or all of the following: (i) the configuration of conductors 90; (ii) the number of conductors 90; (iii) the density of conductors 90; (iv) the thickness of conductors 90; (v) the material properties of conductors 90; (vi) the general properties of the fused segments 220; (vii) the number of fused segments 220; (viii) the frequency of the fused segments 220; (ix) commercial throughput requirements; (x) the width of the busbars; (xi) other customer specifications; and (xii) other factors that would be apparent to one skilled in the art based on the foregoing list of factors.

[0153] If the designer selects laser welding 800, the designer may select: (i) laser type 802; (ii) laser power 804; (iii) laser beam shape 806; (iv) laser path 808; and / or (v) other factors 810. The laser type 802 can be any type of laser designed for curing, welding, or cutting metal. For example, a laser type 802 that can be used is a fiber-based laser with a wavelength between 688 nm and 1080 nm. The laser power 804 can be any power configured to weld the busbar 100 in the desired manner. For example, the laser power 804 can be between 0.5 kW and 25 kW, preferably between 1 kW and 6 kW, and most preferably between 2 kW and 5 kW. The laser beam shape 806 can also take any desired shape that includes only the center core 820 (e.g., Figure 16A As shown), a ring 822 surrounding the central core 820 (as shown 16B to 16D As shown, a central core and two adjacent cores, wherein the adjacent cores are positioned in front of the central core when using a laser or other similar configuration. Not only can the general shape of the laser beam be controlled, but also the power and size associated with each of these features can be controlled. 16B to 16D An example of how to change these power levels is shown in FIG. Figure 16B Beam shape 806 is shown, wherein central core 820 is set to a first power level, and ring 822 is set to a second power level lower than the first power level. For a reference frame, the central core power can vary between 0.5 kW and 12 kW, preferably between 1 kW and 5 kW, and most preferably between 2 kW and 4 kW, while the ring power can vary between 0.5 kW and 15 kW, preferably between 1 kW and 4 kW, and most preferably between 1 kW and 2.5 kW. Furthermore, the diameter of central core 820 and the diameter of the ring can be varied. For example, these diameters vary between 50 μm and 600 μm.

[0154] After selecting the laser type 802 , laser power 804 , and laser beam shape 806 , the designer may select the laser path 808 . Figures 16E to 16H 8. It should be understood that these laser paths 808 are not the entire path that the laser will follow on the bus bar 100. Rather, these laser paths 808 are a component of the entire path that the laser will follow. For example, the laser can oscillate in a circular path 832 while following a sinusoidal pattern on top of the bus bar 100. Alternatively, the laser can oscillate in a circular path 832 while following a linear edge of the bus bar 100. Figures 16F to 16GAs shown, shapes other than circles may be followed, such as a line 834, a figure eight 836, or an infinity symbol 838. Finally, the designer may select other variables such as processing time, cooling time, etc.

[0155] Instead of using a laser-based fusion process, the designer may choose to use a resistance spot welding fusion process 900. Here, the designer will select: (i) the manufacturing mode 902; (ii) the power level applied to the electrode 904; (iii) the roller type 906, if the batch manufacturing mode was selected in 902; and (iv) other similar variables 908. Figures 73 to 78 This process is discussed in more detail. It should be understood that the designer may choose to use any of the above fusing methods in combination with applying external pressure to the conductor 90 to maintain the proper arrangement of the conductor 90 as it undergoes this fusing process.

[0156] It should also be understood that different fusing methods may be used in conjunction with different portions, sections, or regions of the busbar 100. For example, the end portion 700 may be formed using a resistance welding method 900, while the middle portion 200 may be formed using a laser welding method 800. In yet another alternative embodiment, the fused segments 220 may be created using a process that deposits material around the conductors 90 within the busbar 100. For example, this may be done using a 3D printer, or a sleeve of material may be slid over the conductors 90 to form the fused regions 220. After selecting fusing methods for the identified segments within the middle portion 200 and end portion 700 in step 114, the designer proceeds to determine a combined pattern of the identified fused segments 220 within the middle portion 200 of the busbar 100.

[0157] return Figure 6Once the fusing method is selected in step 114, the busbar designer can determine a combination pattern for the identified fused segments 220 within the middle portion 200 of the busbar 100 in step 118. Since the general characteristics of each fused segment 220 have been identified in conjunction with step 110, step 118 focuses on converting these general characteristics (e.g., 250a, 254a, 258a) into manufacturable characteristics. The designer analyzes these general characteristics (e.g., 250a, 254a, 258a), characteristics associated with the selected fusing process, and other relevant characteristics to determine a combination pattern for the identified fused segments 220. This combination pattern, or (specifically) the segment combination pattern 300, can be generated from two components: a top segment fused pattern 304, 306a-306g and a bottom segment fused pattern 308, 310a-310g. Forming the segmented pattern 300 from these two components 304, 308 is desirable because fusion methods are typically configured to only partially penetrate the conductors 90 contained within the busbar 100 due to the fact that full penetration of all conductors 90 may mechanically weaken the busbar 100. To reduce the number of fully solidified areas, the busbar 100 is welded from the top of the busbar 100 and the bottom of the busbar 100 in a manner that does not fully penetrate all conductors 90 contained within the busbar 100. In other words, the top weld and the bottom weld are typically configured as partially solidified areas. Figures 36 to 47 While it may be desirable to split segment pattern 300 into two components, it should be understood that segment pattern 300 can remain a single component and that fusing of segments 220 can occur on only a single side of busbar 100 (eg, top or bottom).

[0158] Creating the top fused pattern 304 and the bottom segment fused pattern 306 (which together form the segment combined pattern 300) is a combination of Figure 17A The multi-step process described herein is described. Here, the first step in the process is to select the number of waveforms 320 in step 124. The number of waveforms 320 that can be selected can be any number (e.g., 0-100), preferably between 1-6, and most preferably two waveforms 330, 340. Using two waveforms 330, 340 is desirable because: (i) the waveforms 330, 340 can be arranged to minimize the distance along the edge of the busbar 100 that does not contain a weld; and (ii) this limits the area that will overlap with the bottom fusion pattern 306. After selecting the number of waveforms 320 in step 124, the designer can select the type of waveform 320 in step 126. 18A to 18R Example waveform types are shown in FIG. 18. Examples of waveforms included in FIG. 18 are: (i) sine wave ( Figure 18A ); (ii) triangle ( Figure 18B ); (iii) ramp up ( Figure 18C ); (iv) Slope down ( Figure 18D ); (v) square ( Figure 18E ); (vi) pulse ( Figure 18F ); (vii) line ( Figure 18G ); (viii) dome pulse ( Figure 18H ); (ix) circular pulse ( Figure 18I ); (x) triangle pulse ( Figure 18J ); (xi) Ramp pulse ( Figure 18K ); (xiii) sine cube ( Figure 18L ); (xiii) flame ( Figure 18M ); (ixv) semicircle ( Figure 18N ); and (xv) other waveforms ( Figures 18O to 18R ). It may be desirable to use waveforms 320 that include curved shapes because these waveforms do not include multiple sharp angles that may introduce additional stresses to the busbar when the busbar 100 is manipulated. However, if the designer takes adequate precautions (e.g., only using them in segments that will experience out-of-plane bending 760), waveforms that include sharp angles can be used. In addition, it should be understood that the waveform types shown in FIG. 18 are merely exemplary waveform types, and other types may be used.

[0159] Once the designer has selected a waveform type in step 126, the designer then selects the amplitude of the waveform 320 in step 128 and the frequency of the waveform 320 in step 130. While any amplitude can be selected in step 128, it may be desirable to select an amplitude for the waveform 320 that allows the apex of the waveform to be close to the edge of the busbar 100, but not extend beyond the edge of the busbar 100. This may be desirable because, if the designer is using the laser welding fusion process 800, this will reduce weld spatter and, in turn, reduce the number of sharp edges contained within the busbar 100. Similarly, while any frequency can be selected in step 130, it should be understood that the frequency of the waveform 320 is one of the dominant factors in varying the characteristics of the busbar 100. Thus, the frequency of waveform 320 should be selected so that the top section weld pattern 304 meets a portion of the general characteristic requirements (e.g., 250a, 254a, 258a), which in turn allows the welded area to meet the requirements associated with bending, and which in turn allows the busbar 100 to meet at least a portion of the customer specifications 50 received in step 52. Once this process is completed for the top section weld pattern 304, the designer can perform the same steps to create the bottom weld pattern 308. Specifically, the designer will do the following: (i) select the number of waveforms in step 134; (ii) select the waveform type in step 136; (iii) select the amplitude in step 138; and (iv) select the frequency in step 140.

[0160] Finally, after creating both the top segment fusion pattern 304 and the bottom segment fusion pattern 308, the designer may then align these patterns 304, 308 on the busbar 100 in step 142 to form the segment combination patterns 300, 302a-302g. Specifically, it may be desirable to align the patterns 304, 308 in a manner that minimizes overlap between the patterns 304, 308, as their alignment or intersection will create fully cured areas. For example, the designer may offset the patterns 304, 308 by 90 degrees in order to minimize this overlap. Other methods of minimizing the number of fully cured areas include: (i) stopping and starting the waveform 320 to avoid creating overlapping areas; (ii) reducing the number of conductors 90 that are fused within these overlapping / intersecting areas / points by the selected fusion process; or (iii) selecting a different waveform type that minimizes the number of overlapping areas (see Figure 21B ).

[0161] In summary, the combined segment fuse pattern 300, 302a-302g includes a top segment fuse pattern 304, 306a-306g and a bottom segment fuse pattern 308, 310a-310g, wherein the top fuse pattern 304 and the bottom fuse pattern 308 include at least one waveform 320 having an amplitude and a frequency. It should be understood that in alternative embodiments, the top segment fuse pattern 304 or the bottom segment fuse pattern 308 may be omitted, may include only a single waveform, and / or the waveform may be a straight line (i.e., having a zero amplitude).

[0162] As discussed above, in step 110, a number of factors are considered in planning the general characteristics of each fused segment 220 (e.g., 250a, 254a, 258a), which in turn means that a number of factors are also considered in generating the segment combination pattern 300. In considering these many factors, it should be understood that the bend geometry may be one of the dominant factors in determining the type, amplitude, and frequency of the waveform. This is because the forces exerted on the conductors 90 contained within the busbar 100 are significantly different with respect to the out-of-plane bend 750 as compared to the out-of-plane bend 760. Furthermore, as discussed above, the frequency of the waveform 320 is one of the dominant factors in varying the characteristics of the busbar 100 within the fused segment 220. Taking these particular factors into account, it can be seen that the frequencies of the waveforms contained within the segment combination patterns 302b, 302c are in the range FIG. 20A to FIG. 20B This increase in frequency is intended to illustrate the following facts: Figure 20A It is designed for out-of-plane bending 760, and Figure 20BIt is designed for in-plane bending 750. Another dominant factor that changes the characteristics of the busbar 100 within the fused segment 220 is the width of the busbar 100. Taking this and other factors into account, it can be seen that the frequency of the waveform contained in the segment combination pattern 302d, 302e is between FIG. 20C to FIG. 20D This increase in frequency is intended to illustrate the following facts: Figure 20C is designed for busbars with a first width, and Figure 20D It is designed for a busbar having a second width that is larger than the first width.

[0163] It should be understood that the number, type, amplitude, and frequency of the waveforms included therein may be: (i) consistent across the entire fused section 220; or (ii) inconsistent across the entire fused section 220. For example, the frequency of the waveform 320 may vary within a single fused section 220. Figures 21A to 21B , which depicts examples of segment patterns 302f and 302g containing waveforms having varying frequencies. Specifically, the waveforms contained within these segment patterns 300 increase in frequency as they approach the center of the fused segment 220. This configuration may be desirable if the center of the fused segment 220 is centered over a bend in the busbar 100, as it would provide additional rigidity to the busbar 100 in this area, which in turn would reduce the likelihood of delamination of the conductors 90 contained within the busbar 100. Furthermore, it should be understood that the designer may vary other variables to achieve the desired characteristics of the busbar 100. Examples include, but are not limited to: (i) the width of each of the waveforms 330, 340, 350, 360 may be the same, different, or may vary across the fused segment 220; and (ii) the number of conductors 90 solidified by each waveform 330, 340, 350, 360 may be the same, different, or may vary across the fused segment 220.

[0164] Similar to the process described above in connection with determining the pattern of the identified fused segments 220 in step 118, the busbar designer can determine the pattern of the end portion 700 of the busbar 100 in step 150. Specifically, the end pattern 400 can be determined based on the connector that the designer plans to attach to the busbar 100. For example, the first end pattern 400a can be used in connection with an end portion 700 designed to receive a connector 2000, while the second end pattern 402b can be used with an end portion 700 designed to receive a hole formed therethrough. After selecting the desired characteristics, the designer can follow the same steps described above in connection with determining the segment pattern 300. Specifically, the top fused pattern 404 is determined in step 154 ​​by: (i) selecting the number of waveforms in step 156; (ii) selecting the type of waveform in step 158; (iii) selecting the amplitude of the waveform in step 160; and (iv) selecting the frequency of the waveform in step 162. Next, the bottom fuse pattern 410 is determined in step 164 by: (i) selecting the number of waveforms in step 166; (ii) selecting the type of waveform in step 168; (iii) selecting the amplitude of the waveform in step 170; and (iv) selecting the frequency of the waveform in step 172. Finally, in step 174, the top fuse pattern 404 and the bottom fuse pattern 410 are arranged in a manner that minimizes the overlap between the top fuse pattern 404 and the bottom fuse pattern 410 in step 174. Figures 22A to 22E As shown, the end combination pattern 400 can take the following forms: (i) overlapping rectangles 402a, such as Figure 22C (ii) spiral rectangle 402b, as shown; Figure 22B or (iii) a spiral circular 402c, such as Figure 22C It will be appreciated that either the spiral circular 402 or the spiral rectangular 404 may be desirable because there is no overlap between the end fuse patterns 404, 410.

[0165] Once the segment combination pattern 300 and the end combination pattern 400 are determined, the designer can replace the general characteristics (e.g., 250a, 254a, 258a) with these combination patterns 300, 400. FIG. 23A to FIG. 23B An example of such replacement is shown. FIG. 14A to FIG. 14B The general characteristics of the exemplary busbar model 100 250, 254, 258, 262 are determined by satisfying FIG. 23A to FIG. 23B The combination of these general characteristics in the pattern 300, 400 is replaced. First focus on Figure 23A1 and label design 1 (along the right side of the figure), the middle portion 200 includes: (i) two fused segments 220, 251a-251b; and (ii) one unfused segment 520, 252. The general characteristic 250a of the fused segments 220, 251a-251b has been replaced by segment combination patterns 452a-452b, wherein each pattern 452a-452b includes a top fused pattern 453 shown in solid lines and a bottom fused pattern 454 shown in dashed lines. The top fused pattern 453 and the bottom fused pattern 454 are composed of two waveforms 320, wherein each waveform 320 has a sinusoidal waveform type, an amplitude slightly less than the width of the busbar 100, a consistent frequency, and is offset 180 degrees from the other waveform 320. The top fused pattern 453 and the bottom fused pattern 454 are offset 90 degrees from each other to minimize their overlap. As described above, the unfused segments 520, 252 positioned between the fused segments 251a-251b remain bonded to the upper Figure 14A The same features 250b as described for label design 1 are shown, as this area of ​​the busbar 100 is not modified by the fusing process. Finally, the end portions 700, 702a, 702b have been modified to include end combination patterns 456a-456b, where each pattern 456a-456b includes a top fusion pattern 457 shown in solid lines and a bottom fusion pattern 458 shown in dashed lines. The top fusion pattern 457 and the bottom fusion pattern 458 are composed of concentric rectangles that are offset from each other to minimize their overlap.

[0166] Next follow Figure 23AIn the case of label design 2, the middle portion 200 includes: (i) four fused segments 220, 253a-253d; and (ii) one unfused segment 520, 256. The general characteristic 254a of the first two fused segments 220, 253a-253b has been replaced by segment combination patterns 462a-462b, each of which includes a top fused pattern 463a shown in solid lines and a bottom fused pattern 464a shown in dashed lines. The top fused pattern 463a and the bottom fused pattern 464a are composed of two waveforms 320, each of which has a sinusoidal waveform type, an amplitude slightly less than the width of the busbar 100, a consistent frequency, and is offset 180 degrees from the other waveform. The top fused pattern 463a and the bottom fused pattern 464a are offset 90 degrees from each other to minimize overlap. The general characteristics 254b of the first two fused segments 220, 253c-253d, have been replaced by segment combination patterns 462c-462d, where each pattern 262c-462d includes a top fused pattern 463b, shown in solid lines, and a bottom fused pattern 464b, shown in dashed lines. Top fused pattern 463b and bottom fused pattern 464b are composed of two waveforms 320, each of which has a sinusoidal waveform type, an amplitude slightly smaller than the width of busbar 100, a consistent frequency, and is offset 180 degrees from the other waveform. Top fused pattern 463b and bottom fused pattern 464b are offset 90 degrees from each other to minimize overlap.

[0167] like Figure 23A As shown in labeled Design 2, the waveform contained within the segment combination pattern 462c-462d has a lower frequency than the waveform contained within the segment combination pattern 462a-462b. This lower frequency is selected because the segments 253c, 253d are configured to bend out of plane 760, while the segments 253a, 253b are configured to bend in plane 750. As described above, the unfused segments 520, 256 positioned between the fused segments 253a remain bonded to the upper Figure 14A The same feature 254c as described for labeled design 2 is shown, as this area of ​​the busbar 100 is not modified by the fusing process. The end portions 700, 702a, 702b have been modified to include end combination patterns 466a-466b, where each pattern 466a-466b includes a top fusing pattern 467 shown in solid lines and a bottom fusing pattern 468 shown in dashed lines. The top fusing pattern 467 and the bottom fusing pattern 468 are composed of concentric rectangles that are offset from each other to minimize their overlap.

[0168] Next follow Figure 23BIn the example of label design 3, the middle portion 200 includes: (i) ten fused segments 220, 259a-259j; and (ii) one unfused segment 520, 260. The general characteristic 254a of the four fused segments 220, 259a-259d has been replaced by segment combination patterns 472a-472d, each of which includes a top fused pattern 473a, shown in solid lines, and a bottom fused pattern 474a, shown in dashed lines. The top fused pattern 473a and the bottom fused pattern 474a are composed of two waveforms 320, each of which has a sinusoidal waveform type, an amplitude slightly less than the width of the busbar 100, a consistent frequency, and is offset 180 degrees from the other waveform 320. The top fused pattern 473a and the bottom fused pattern 474a are offset 90 degrees from each other to minimize overlap. The general characteristics 254b of the other six fused segments 220, 259e-259j, have been replaced by segment combination patterns 472e-472j, wherein each pattern 272e-274j includes a top fused pattern 473b shown in solid lines and a bottom fused pattern 474b shown in dashed lines. The top fused pattern 473b and the bottom fused pattern 474b are composed of two waveforms 320, wherein each waveform 320 has a sinusoidal waveform type, an amplitude slightly less than the width of the busbar 100, a consistent frequency, and is offset 180 degrees from the other waveform 320. The top fused pattern 473b and the bottom fused pattern 474b are offset 90 degrees from each other to minimize their overlap.

[0169] like Figure 23B As shown in the labeled design 3, the waveform contained in the segment combination pattern 472c-472d has a higher frequency than the waveform contained in the segment combination pattern 472e-472j. This higher frequency is selected because the segments 259a-259d are configured to bend 750 in a plane, while the segments 259e-472j are configured to take into account the forces radiated from the four in-plane bends 750 in the segments 259a-259d. As described above, the unfused segments 520, 260 positioned between the fused segments 259e, 259h remain bonded to the above Figure 14A The same feature 258c as described for labeled design 3 is shown, as this area of ​​the busbar 100 is not modified by the fusing process. The end portions 700, 702a, 702b have been modified to include end combination patterns 476a-476b, where each pattern 476a-476b includes a top fusion pattern 477 shown in solid lines and a bottom fusion pattern 478 shown in dashed lines. The top fusion pattern 477 and the bottom fusion pattern 478 are composed of concentric rectangles that are offset from each other to minimize their overlap.

[0170] Next follow Figure 23BIn the case of label design 4, the middle portion 200 includes: (i) four fused segments 220, 263a-263d; and (ii) one unfused segment 520, 264a-264e. The general characteristic 262a of the four fused segments 220, 263a-263d has been replaced by segment combination patterns 482a-487d, each of which includes a top fused pattern 483a, shown in solid lines, and a bottom fused pattern 484a, shown in dashed lines. The top fused pattern 483a and the bottom fused pattern 484a are composed of two waveforms 320, each of which has a sinusoidal waveform type, an amplitude slightly less than the width of the busbar 100, a consistent frequency, and is offset 180 degrees from the other waveform 320. The top fused pattern 483a and the bottom fused pattern 484a are offset 90 degrees from each other to minimize overlap. As described above, the unfused segments 520, 264a-264e positioned between the fused segments 263a-263d remain bonded to the upper Figure 14B The same feature 264c as described for tabbed design 4 is shown, as this area of ​​the busbar 100 is not modified by the fusing process. The end portions 700, 702a, 702b have been modified to include end combination patterns 486a-486b, wherein each pattern 486a-486b includes a top fusing pattern 487 shown in solid lines and a bottom fusing pattern 488 shown in dashed lines. The top fusing pattern 487 and the bottom fusing pattern 488 are composed of concentric rectangles that are offset from each other to minimize their overlap.

[0171] Once the engineering models 100 are created, the designer can digitally test these models 100 (e.g., Figure 23A 450) to determine whether the busbar manufactured based on model 100 meets customer specifications 50. Here, model 100 is bent using a digital bending machine 179, and the electrical characteristics of model 100 are tested using a voltage testing system 181. This testing can be performed using a finite element (FE) busbar model 100. If the busbar model 100 passes these tests, the designer can proceed to the next step in the process. However, if the busbar model 100 fails these tests 179, 181, the designer can restart the design process.

[0172] B. Manufacturing of the Busbar of the Invention

[0173] return Figure 4 Once the engineering model 100 passes the digital tests presented in step 180, the designer can begin the manufacturing process in step 182. The manufacturing process 182 is a multi-step process. Figure 25At a high level, the process 182 includes the following steps: (i) obtaining a plurality of conductors 1090; (ii) fusing identified segments 1220 within the middle portion 1200 according to the engineering model 100 in step 184; (iii) fusing the end portions 1700 of the busbar 1000 in step 186 according to the engineering model 100; (iv) adding selected edge details to the busbar 1000 in step 188; and (v) performing optional manufacturing steps, such as adding connectors in step 190, insulating the busbar 1000 in step 192, and / or plating a portion of the busbar 1000 in step 194.

[0174] like Figure 25 As shown, the first step in this multi-step process 182 is to obtain a plurality of conductors 1090 and then fuse the identified segments 1220 within the middle portion 1200 in accordance with the engineering model 100 in step 184. To perform this step 184, the busbar designer / manufacturer obtains the conductors 1090 and then uses a machine 798 that is capable of performing the fusion method selected when creating the engineering model 100. For example, if the designer decides to use a laser welding fusion method, the designer will use at least Figures 26 to 28 、 Figure 48A 、 Figure 49A 、 Figures 52 to 53 . As shown in these figures, the laser welding machine 850 includes two separate lasers 852, 854 that can weld the busbar 1000 from both the top and bottom simultaneously. The two separate lasers 852, 854 are preferably aligned in a horizontal plane. However, it should be understood that the laser welding machine 850 can have other configurations, including: (i) only one laser 852 that can interact with only one side of the busbar 1000 at a time; (ii) only one laser 852, but using optics and mirrors to modify the light output from the laser so that the laser can interact with both sides of the busbar 1000 simultaneously; or (iii) two lasers 852, 854 that are not aligned.

[0175] like Figure 26 As shown, after the designer acquires or obtains access to the laser welding machine 850, the designer will do the following: (i) insert the conductor 90 arranged according to the engineering model 100 into the machine; and (ii) load the engineering model 100. The laser welding machine 850 will then perform the welding process described in the engineering model 100. For example, Figure 26 Shown based on Figure 23Aand the laser welding machine 850 that creates the weld 1600 with the top fusion pattern 452a shown in the label design 1. After the laser welding machine 850 performs the welding process in step 186, the machine 850 performs the fusing of the end portion 1700 of the busbar 1000 in accordance with the engineering model 100 in step 186. Specifically, it can be combined with Figure 27 See the steps, where Figure 23A The end portion 1700 of the busbar 1000 is welded 1600 to the top weld pattern 456a shown in tabbed design 1. In creating the welded section 1220, the designer / manufacturer has at least made the section 1220 of the busbar more rigid or stiffer than the section 1220 was before the welding process 1600 was performed.

[0176] After the top and bottom surfaces of the busbar 1000 have undergone the welding process associated with steps 186, 187, edge detail is added to the busbar 1000 in step 188. Figure 28 In the example shown, the edge detail is selected for this example FIG. 12C to FIG. 12D 106. This edge detail may have been selected during the design phase because it: (i) helps fuse the edge portions of the busbar 1000 that typically experience significant stress when the busbar 1000 is bent; and (ii) helps ensure that any material that is pressed against the edge of the busbar 1000 during the top and bottom welding processes is rounded off, thereby preventing the busbar 1000 from having sharp edges that could create holes in the insulator. Specifically, Figure 28 A welding machine 850 is shown that includes a laser 852 that can create welds 1600 on the edges or sides of the busbar 1000. These welds 1600 follow a previously selected circular pattern ( Figure 16E ). It will be appreciated that this step can be omitted from the process, or that the weld pattern can be changed to a different pattern (e.g., increasing the laser intensity at the edge portions and decreasing the laser intensity at the center of the busbar 1000). It will be appreciated that the weld depth on the edges or sides can vary within the busbar 1000, or can be varied for a particular application.

[0177] Manufacturing steps 184, 186, 188 result in Figure 23A and the engineering model 100 shown in the label design 1 is formed Figures 29 to 35 Busbar 1000 is shown. It should be understood that busbar 1000 is an exemplary embodiment of a busbar of the present invention and that the present disclosure contemplates other embodiments disclosed herein. Figures 29 to 35 As shown, busbar 1000 comprises: (i) a middle portion 1200; and (ii) two end portions 1700. Figure 29, the middle portion 1200 extends between the end boundary lines 1200a, 1200b, and the end portion 1700 extends outward from the end boundary lines 1200a, 1200b. The middle portion includes: (i) two fused segments 1220; and (ii) one unfused segment 1520. In addition, Figure 29 In the embodiment shown in FIG, the fused section 1220 extends between the end boundary lines 1200a, 1200b and the intermediate boundary lines 1220a, 1220b. The unfused section 1520 is not welded and therefore contains an unsolidified area 1670. Therefore, the range of each conductor 1090 is between Figures 29 to 35 The fused segment 1220 is created by welding 1600 generated based on the top fused pattern 453 and the bottom fused pattern 454 of the segment combined fused pattern 452a, as shown in FIG. Figure 23A and the labelled design shown in 1.

[0178] The welds 1600, 1602 contained within the fused section 1220 include four waveforms 1610, 1612, 1614, 1616, two of which are disposed on the top surface 1000a of the busbar 1000, and two of which are disposed on the bottom surface 1000b of the busbar 1000. Each of the four waveforms 1610, 1612, 1614, 1616 is a sine wave having an amplitude less than the width of the busbar 1000 and a frequency that is consistent across the entire fused section 1220. The top sine waves 1610, 1612 are arranged so that they are 180 degrees out of phase with each other. The bottom sine waves 1614, 1616 are arranged so that they are 180 degrees in phase with each other. Additionally, the combination of top sine waves 1610, 1612 is 90 degrees out of phase with the combination of bottom sine waves 1614, 1616. Additionally, the sides or edges of busbar 1000 also include welds 1600, 1606 based on the selected edge details 106. Furthermore, end portion 700 is created by weld 1600 generated based on top and bottom weld patterns 457, 458 of end combined weld pattern 456a, as shown. Figure 23A and as shown in Label Design 1. Here, the top fuse pattern 457 and the bottom fuse pattern 458 comprise concentric rectangles.

[0179] Figures 37 to 39 Shown Figure 37, wherein the top surface 1000a of the busbar 100 includes welds 1600, 1602, 1604. Transecting the busbar 1000 along the longitudinal centerline 37-37 shows that: (i) the weld 1602 creates a partially solidified region 1650 in the fused section 1220 of the middle portion 1200 of the busbar 1000; (ii) the weld 1604 creates a densified end portion 1700; and (iii) the area that has not undergone the welding process remains unsolidified 1670. The partially solidified region 1650 is formed within the fused section 220 of the middle portion 200 because the welding process combines some, but not all, of the conductors 1090 contained within the partially solidified region 1660 into a single consolidated conductor. Figure 39 , the partially solidified region 1650 extends from the first surface 1000a of the busbar 1000 to the peak 1656 of the weld 1600. The weld peak 1656 is located at a point between the first surface 1000a and the second surface 1000b of the busbar 1000, and preferably a significant distance inward from the first surface 1000a and the second surface 1000b. The partially solidified zone is the area 1660 of the busbar 1000 that has undergone the partial penetration welding process, extending between the top surface 1000a and the bottom surface 1000b. The height of the partially solidified zone 1660 extends between the first surface 1000a and the second surface 1000b. In other words, the height of the partially solidified zone 1660 is equal to the fusion section height H. F And greater than the partial solidification height H P The width Z of the partially cured area 1660 is W At least equal to the diameter or cross-sectional width of the partially solidified zone 1650 .

[0180] Weld depth D of weld 1600 W Extends from the first surface 1000a to the weld peak 1656. The weld depth D in the partially solidified region 1650 is W With partially cured height H P . Partially cured height H P Less than the total fusion section height or thickness H of busbar 1000 F Due to the partially cured height H P Less than the fusion section height H F , thus forming an uncured region 1670 between the weld peak 1656 and the second surface 1000b of the busbar 1000. The uncured region 1670 has an uncured height H U , which extends between the second surface 1000b and the peak 1656 of the weld 1600. The uncured height H U Usually the fusion section height H F At least 10%, preferably at the fusion section height H FOn the other hand, the partially cured height H P Equal to the fusion section height H F At least 10%, preferably at the fusion section height H F between 35% and 80%, most preferably at the fusion section height H F between 45% and 70%.

[0181] In this exemplary embodiment, partially cured regions 1650 may be created by curing between two and nine conductors 1090. Here, Figure 39 Approximately seven of the ten conductors 1090 are shown as being cured in partially cured region 1650. In other words, not all (approximately three) of the conductors 1090 are uncured, and therefore, these conductors 1090 are located in uncured region 1670. In other words, the middle portion 1200 of the busbar 1000 includes a plurality of conductors 1090 that traverse or span the middle portion 1200 of the busbar 1200. The fused section 1220 of the middle portion 1200 includes a partially cured zone 1660 that extends between the uppermost surface 1000a of the plurality of conductors and the lowermost surface 1000b of the plurality of conductors. The majority of the conductors 1090 contained within this partially cured zone 1660 have been cured into a single, consolidated conductor to form partially cured region 1650. Likewise, a small portion of the conductors 1090 contained within this partially cured zone 1660 is uncured.

[0182] like Figure 39 As best shown in FIG. 1 , partially solidified region 1650 comprises varying fusion densities, with a first or inner zone 1652 having a first fusion density and a second or outer zone 1654 having a second fusion density less than the first fusion density. The density difference is caused by the configuration and operational conduction of laser welder 850, where the laser beam loses intensity as it penetrates busbar 1000. Lower density zone 1654 is created a distance outward from the center of weld 1600, or outside higher density zone 1652. It should be understood that this second zone 1654 can have a fusion density gradient, with a higher fusion density closest to first zone 1652 and a lowest fusion density at a point farthest from first zone 1652. It should also be understood that within first zone 1652, the fusion density can be uniform or substantially uniform. Additional aspects of partially solidified region 1650 and unsolidified region 1670 are presented in the definitions section at the beginning of the detailed description.

[0183] In a first non-limiting example, for a system comprising 10 copper conductors 1090 (whose height or thickness H C=0.01 inches or 0.254 mm), the settings that can be used in conjunction with the laser welding machine 850 are: (i) the laser type is a fiber laser; (ii) the laser power is 2000W; (iii) the laser beam shape is a center core; (iv) there is no laser path; and (v) the cycle time is set to 0.116 seconds. These settings of the machine 850 form a partially solidified area that extends about 56% of the way into the busbar 1000 and has a diameter of about 0.24 mm at its widest point. In another example, for a busbar 1000 comprising 10 copper conductors 1090 (whose height H is 0.01 inches or 0.254 mm), the settings that can be used in conjunction with the laser welding machine 850 are: (i) the laser type is a fiber laser; (ii) the laser power is 2000W; (iii) the laser beam shape is a center core; (iv) there is no laser path; and (v) the cycle time is set to 0.116 seconds. C =0.01 inches or 0.254 mm), the settings that can be used in conjunction with the machine 850 are: (i) the laser type is a fiber laser; (ii) the power of the laser is 5000 W; (iii) the laser beam shape is a center core with a ring, where the core power is 1500 W and the ring power is 3500 W; (iv) there is no laser path; and (v) the cycle time is set to 0.079 seconds. These settings of the machine 850 form a partially cured area 1650 that extends approximately 77% of the way into the busbar 1000 and has a diameter of approximately 0.732 mm at its widest point. In another example, for a busbar 1090 comprising 10 copper conductors 1090 (whose height H is 0.01 inches or 0.254 mm), the settings that can be used in conjunction with the machine 850 are: (i) the laser type is a fiber laser; (ii) the power of the laser is 5000 W; (iii) the laser beam shape is a center core with a ring, where the core power is 1500 W and the ring power is 3500 W; (iv) there is no laser path; and (v) the cycle time is set to 0.079 seconds. C =0.01 inches or 0.254 mm), the settings that can be used in conjunction with the machine 850 are: (i) the laser type is a fiber laser; (ii) the laser power is 5000 W; (iii) the laser beam shape is a central core with a ring, where the core power is 1500 W and the ring power is 3500 W; (iv) there is no laser path; and (v) the cycle time is set to 0.158 seconds. These settings of the machine 850 form a partially cured area that extends approximately 79% of the way through the busbar 1000 and has a diameter of approximately 0.732 mm at its widest point.

[0184] In addition to containing partially cured regions 1650, the fused section 1220 within the middle portion 1200 of the busbar 1000 also contains uncured regions 1670. As shown, a majority of the volume contained within the fused section 1220 contains uncured regions 1670. The large volume of 1670 ensures that the characteristics of the busbar 1000 include attributes of both the rigid busbar 10 and the flexible busbar 20. It should be understood that Figures 37 to 39 Only a portion of the solidified region 1650 is shown because the cross section 37 - 37 is taken along a range of the busbar 1000 that does not include overlapping or intersecting welds extending from the top and bottom of the busbar 1000 . Figure 37Also shown is a cross-section of the end portions 1700 of the busbar 1000. Unlike the middle portion 1200, the end portions 1700 are intended to receive connectors, and therefore it is desirable that these areas be fully solidified into a single, consolidated conductor. As discussed above, the end portions 1700 are welded in such a way that these portions are densified (solidified surface area sufficient, equivalent to 120% of the cross-sectional area of ​​the busbar 100) so that they can be coupled to the connector.

[0185] Go to Figures 40 to 43 , the cross-sectional plane of busbar 1000 is offset from the longitudinal center 1000c of busbar 1000 toward the peripheral edge 1000e and is located at the locations where the top weld 1602 formed by top surface 1000a intersects the bottom weld 1602 formed by bottom surface 1000b. These intersection locations form fully solidified regions 1690 because a significant extent of conductor 1090 solidifies downward from top surface 1000a and a significant extent of conductor 1090 solidifies upward from bottom surface 1000b. Thus, these significant extents of conductor 1090 meet between top surface 1000a and bottom surface 1000b, generally in the midpoint region between the two surfaces 100a, 100b, and form fully solidified region 1690. The weld depth D in fully solidified region 1690 is 0.001mm / s. W With fully cured height H FS . Fully cured height H FS Basically equal to the fusion section height H of busbar 1000 F In certain exemplary embodiments, when the weld material is deposited onto one of the two surfaces 100a, 100b, the fully solidified height H FS Can be greater than the fusion section height H F , thus producing a "dome effect". Due to the weld depth D W Equal to or greater than the fusion section height H F , and therefore, no unsolidified area 1670 is formed between the weld and the second surface 1000b of the busbar 1000. In other words, all of the intermediate range of the conductor 1090 positioned within the fully solidified zone 1688 is solidified into a single consolidated conductor. Additional aspects of the fully solidified zone 1690 are presented in the definition section at the beginning of the detailed description. Like the partially solidified zone 1660, the fully solidified zone 1688 is the area of ​​the fused section 1220 of the intermediate portion 1200 of the busbar 1000, which extends between the top surface 1000a and the bottom surface 1000b, that has undergone a partial penetration welding process. The height of the fully solidified zone 1688 extends between the first surface 1000a and the second surface 1000b. In other words, the height of the fully solidified zone 1660 is equal to the fused section height H F and can be equal to the fully cured height H FSThe width Z of the fully cured area 1688 w At least equal to the diameter or cross-sectional width of the fully cured zone 1690 .

[0186] As with the partially solidified region 1650, the fully solidified region 1690 includes varying fusion densities, wherein a first or inner zone 1692 has a first fusion density and a second or outer zone 1694 has a second fusion density that is less than the first fusion density. The difference in fusion density is caused by the configuration and operating parameters of the machine 850, wherein the laser beam loses intensity as it penetrates into the bus bar 1000 and, as a result, produces a lower density zone 1694 a distance outward from the center of the weld 1600 or outside of the higher density zone 1694. It should be understood that this second zone 1694 can have a fusion density gradient having a higher fusion density closest to the first zone 1652 and a lowest fusion density at the point farthest from the first zone 1652. It should also be understood that within this first zone 1652, the fusion density can be uniform or substantially uniform. As Figure 42 and Figure 43 As shown, uncured region 1670 surrounds fully cured region 1690 such that individual conductors 1090 in uncured region 1670 remain distinct unfused components.

[0187] Figures 44 to 45 Shown along the Figure 44 A cross-sectional view of busbar 1000 is taken along the cross-sectional plane defined by line 45-45 and shows various regions that have been partially cured and fully cured. Figure 45 The middle range of FIG. 1 shows three partially solidified regions 1650, with the two outer regions 1650 formed by the bottom welding process and the middle region 1650 formed by the top welding process. Next, the opposing side edge regions 1693 are solidified using side edge welds 1606 formed from the circular edge details 106 included in the busbar model 100 used to create the busbar 1000. These edge welds 1606 form fully solidified edge regions 1693 that extend inwardly from the outer perimeter or side edges 1000d, 1000e of the busbar 1000. Specifically, these fully solidified edge regions 1693 extend from the first perimeter edges 1000d, 1000e to the inner weld boundary 1696 and thus have a width W W , where W w The edge detail 106 may be between 0.2 mm and 5 mm or preferably between 0.2 mm and 1 mm. In addition to solidifying the edges 1000d, 1000e of the busbar 1000, the edge detail 106 also rounds the corners 1698 of the busbar 1000. These rounded corners 1698 help reduce the likelihood of the conductor 1090 abrading or tearing the insulator 1780.

[0188] Figures 46 to 47 Shown along by Figure 46 The cross-sectional view of the busbar 1000 is taken along the cross-sectional plane indicated by line 47-47, and shows a plurality of regions that have been fully cured. Figure 47 The middle range of FIG. 1 shows two fully cured regions 1690 adjacent to the uncured region 1670. Next, opposing edge regions 1693 are cured using edge welds 1606 formed from the circular edge details 106 included in the busbar model 100 used to create the busbar 1000. These edge welds 1606 form fully cured edge regions 1693 that extend inwardly from the outer peripheral edges 1000d, 1000e of the busbar 1000. Specifically, these fully cured edge regions 1693 extend from the first peripheral or side edges 1000d, 1000e to the inner weld boundary 1696 and thus have a width W W , where W W The edge detail 106 may be between 0.2 mm and 5 mm or preferably between 0.2 mm and 1 mm. In addition to solidifying the edges 1000d, 1000e of the busbar 1000, the edge detail 106 also rounds the corners 1698 of the busbar 1000. These rounded corners 1698 help reduce the likelihood of the conductor 1090 abrading or tearing the insulator 1780.

[0189] like Figures 29 to 33 As shown, busbar 1000 includes a fused section 1220 having a certain length, width, and height. The length extends between end boundary lines 1200a, 1200b and middle boundary lines 1220a, 1220b, the width extends between the edges of busbars 1000d, 1000e, and the height extends between top surface 1000a and bottom surface 100b. The length dimension, width dimension, and height dimension together define a fused section volume V, which can be added together to determine the total fused section volume of busbar 1000. Each of the fused section volumes includes a plurality of fully cured regions 1690, a plurality of partially cured regions 1650, and a substantially uncured cured region 1670. The fused section volume also includes an uncured region 1670 that extends between and around the plurality of fully cured regions 1690 and the plurality of partially cured regions 1650. Figures 29 to 47 In the busbar 1000 shown in FIG, the uncured regions 1670 occupy a majority of the volume of the fused section, while the combination of the partially cured regions 1650 and the fully cured regions 1670 occupy a smaller portion of the volume of the fused section. Additionally, the partially cured regions 1650 occupy more volume of the fused section than the fully cured regions 1670. Furthermore, the fully cured regions 1670 occupy less volume of the fused section than either the partially cured regions 1650 or the uncured regions 1670.

[0190] Further references Figures 29 to 47 , it will be appreciated that increasing the volume of the partially solidified regions 1650 within the volume of the fused section: (i) will at least increase the local stiffness within the fused section 1220; (ii) will tend to increase the stiffness of the middle portion 1200 of the busbar 1000; and (iii) will tend to increase the overall stiffness of the busbar 1000. For example, creating these partially solidified regions 1650 will increase the Young's modulus of the busbar to above 115 gigapascals (GPa) at room temperature. It will also be appreciated that increasing the volume of the fully solidified regions 1690 within the volume of the fused section: (i) will at least increase the local stiffness within the fused section 1220; (ii) will tend to increase the stiffness of the middle portion 1200 of the busbar 1000; and (iii) will tend to increase the overall stiffness of the busbar 1000. Increasing the volume of the fully solidified regions 1690 within the volume of the fused section should have a greater effect on these stiffness parameters than increasing the volume of only the partially solidified regions 1650. Furthermore, adding partially cured regions 1650 and / or fully cured regions 1690 to a fused segment 1220 having only uncured regions 1670 will increase both the local stiffness and the overall stiffness of the fused segment 1220. Furthermore, it will be appreciated that increasing the volume of both partially cured regions 1650 and fully cured regions 1690 within the volume of the fused segment: (i) will at least increase the local stiffness within the fused segment 1220; (ii) will tend to increase the stiffness of the middle portion 1200 of the busbar 1000; and (iii) will tend to increase the overall stiffness of the busbar 1000. Finally, it will be appreciated that increasing the volume of uncured regions 1670 within the volume of the fused segment: (i) will at least increase the local flexibility within the fused segment 1220; (ii) will tend to increase the flexibility of the middle portion 1200 of the busbar 1000; and (iii) will tend to increase the overall flexibility of the busbar 1000.

[0191] As discussed above, the middle portion 1200 can include any number (e.g., 0-1000) of fused regions 1220 and any number (e.g., 0-1000) of unfused regions 1520. For example, the middle portion 1200 can include only a single fused region 1220 or can include only unfused regions 1520. Additionally, the fused section 1220 can include a plurality of waveforms (e.g., 0-100), preferably 1-6 waveforms, and most preferably four waveforms, i.e., 1610, 1612, 1614, 1618. Thus, the fused section 1220 can include any number of partially solidified regions 1650 or fully solidified regions 1690. For example, the fused section 1220 can be nearly solid due to the fact that it includes a large number of fully solidified regions 1690, or it can be nearly unsolidified due to the fact that the fused section only includes a small volume of a single weld 1600 (e.g., a single laser spot). Furthermore, any waveform type, frequency, and amplitude may be utilized to meet customer specifications. Overall, the unfused segments 1520 may perform in a manner similar to conventional flexible busbars 20, and the fused segments 1220 may perform in a manner similar to conventional rigid busbars 10. These integrally formed segments 1220, 1520 provide significant advantages over conventional busbars 10, 20.

[0192] An optional step in forming the busbar 1000 of the present invention includes encapsulating the conductors 1090 in a protective material or insulator 1780 that surrounds a subset of the busbar 1000. The insulator 1780 can be a heat shrink material (e.g., CPX 100 EV from Shawcor). In an alternative embodiment, the insulator 1780 can be a tape or any other type of material that can be used to coat the busbar 1000. In another alternative embodiment, the insulator 1780 can be formed around the busbar 1000 using an insulating machine 1782 that uses Figures 48A to 48D 1784. Specifically, use of this process 1784 helps prevent high scrap rates or micro-traffic HI Pot parts that are formed because the bus bar 1000 can move within the cavity during the injection of the material that will serve as the insulator 1780. Figures 48A to 48D The machine 1782 shown in FIG uses biasing pins 1786a, 1786b that hold the busbar 1000 in the center of the mold 1788. The pins 1786a, 1786b may be biased using springs, magnets, or any other biasing mechanism. Figures 48B to 48C As shown, the pressure generated by the insertion of the insulating material 1790 will force the pins 1786a, 1786b outward from the center, which allows the busbar 1000 to be fully encapsulated by the insulator 1780 and substantially centered within the insulator 1780. Thus, hot spots or scrapped busbars are reduced. Finally, Figure 48E The finished busbar 1000 is shown removed from the mold 1788 and wherein the conductors 1090 of the busbar 1000 are surrounded by the insulator 1780 .

[0193] The insulator 1780 may include an identification device, symbol, logo, or marking (e.g., a name, QR code, or radio frequency identification device ("RFID")) formed within the insulator 1780. These identification devices, symbols, logos, or markings may help the manufacturer ensure that the busbar is installed in the correct location and facilitate tracking / inventory of the busbars 1000. It should be understood that the insulator 1780 may include shielding properties that reduce electromagnetic noise generated by these busbars 1000.

[0194] like Figure 48A 、 Figure 49A As shown, after welding the top, bottom, and sides of the busbar 1000 and forming the joint, the end portion 500 of the busbar 1000 can be formed using a welding machine 850. When forming the end portion 500, a densified weld is created, and then an attachment device is added thereto. The attachment device can be an opening configured to receive a conventional coupler 24 or a boltless connector system 2000 including a spring member 440a, or any other attachment mechanism used with a busbar.

[0195] The boltless connector system 2000 is described in numerous applications owned by the assignee of the present application and incorporated herein by reference. These applications include PCT / US2019 / 36127, PCT / US2019 / 36070, PCT / US2019 / 36010, and PCT / US2018 / 019787, U.S. Patent Application No. 16 / 194,891, and U.S. Provisional Application Nos. 62 / 897,658, 62 / 988,972, and 63 / 058,061. At a high level, FIG. 7, Figures 49A to 49B Figure 63 to Figure 66 、 Figures 79 to 81 、 Figures 83 to 84The scope of system 2000 is illustrated in Figures 2 and 3, which provide various views of male connector assembly 2200. Male connector assembly 2200 includes: (i) a male terminal receiver 2260; and (ii) a male terminal assembly 2430. Male terminal receiver 2260 is formed by an arrangement of terminal receiver sidewalls 2262a-2262d. Sidewalls 2262a-2262d form a bowl-shaped receiver 2266. Receiver 2266 is configured to snugly receive a substantial portion of male terminal assembly 2430. This configuration provides additional rigidity to male terminal assembly 2430 and limits the amount of exposed male terminal assembly 2430. However, the entire male terminal assembly 2430 is not enclosed within male terminal assembly 2260 or body 2226, as this would prevent male terminal assembly 2430 from contacting female terminal assembly 2800. Therefore, to facilitate coupling the male terminal assembly 2430 to the female terminal assembly 2800, the side walls 2262a-2262d each have a male terminal opening 2268a-2268d therethrough. The male terminal openings 2268a-2268d are provided through the middle portion of the side walls 2262a-2262d and are configured to allow the extent of the male terminal assembly 2430 to extend through the side walls 2262a-2262d so that the male terminal assembly 430 can contact the female terminal assembly 2800.

[0196] Figure 7 Figures 49A to 49B Figure 63 to Figure 66 Various views of male terminal assembly 2430 are provided. Specifically, male terminal assembly 2430 includes a spring member 2440a and a male terminal 2470. Male terminal 2470 includes a male terminal body 2472 and a male terminal connecting member or plate 2474. Male terminal connecting plate 2474 is coupled to male terminal body 2472 and is configured to receive a range of busbars 1000 that connect male terminal assembly 2430 to a device external to connector system 2000 (e.g., an alternator). Male terminal body 2472 includes: (i) male terminal side walls 2482a-2482d; and (ii) an arrangement of rear terminal walls 480. The arrangement of male terminal side walls 2482a-2482d is coupled to one another and generally forms a rectangular prism. Male terminal side walls 2482a-2482d include: (i) side wall portions 2492a, 2492c having a generally "U-shaped" configuration; and (ii) contact arms 2494a-2494h. Side wall portions 2492a-2492d are substantially planar and have a U-shaped configuration with a mid-section. Contact arms 2494a-2494h: (i) extend from the mid-section of side wall portions 2492a-2492d; (ii) extend away from rear male terminal wall 2480; and (iii) extend across the contact arm opening.

[0197] The contact arms 2494a-2494h extend at an outward angle away from the rear male terminal wall 2480. When the male terminal assembly 2430 is inserted into the female terminal assembly 2800, this configuration allows the contact arms 2494a-2494h to be deflected or displaced inward by the female terminal assembly 800 and toward the center of the male terminal 2470. This inward deflection is best shown in the figures included in PCT / US2019 / 036010. By ensuring that the contact arms 2494a-2494h are arranged to contact the female terminal assembly 2800, this inward deflection helps ensure that the correct mechanical and electrical connection is created. The male terminal 2470 is typically formed from a single piece of material (e.g., metal). Therefore, the male terminal 2470 is an integral male terminal 2470 and has integrally formed features. In order to integrally form these features, a die-cutting process is typically used to form the male terminal 2470. However, it should be understood that other methods of forming the male terminal 2470 may be used, such as casting or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the male terminal 470 may not be integrally formed or formed as a whole, but may be formed from separate pieces that are welded together.

[0198] Figure 66 A view of a spring member 2440a configured to function with a first embodiment of a male terminal 470 is shown. The spring member 2440a generally includes: (i) arched spring portions 2448a-448d; and (ii) spring arms 2452a-2452h. The arched spring portions 2448a-448d extend between the rear extent of the spring member wall 2444 and the spring arms 2452a-2452h. The spring arms 2452a-2452h are not connected to each other. This configuration allows for omnidirectional movement of the spring arms 2452a-2452h, which facilitates mechanical coupling between the male terminal 2470 and the female terminal assembly 2800. The spring member 2440a is typically formed from a single piece of material (e.g., metal). In order to integrally form these features, the spring member 2440a is typically formed using a die-casting process. As discussed in more detail below and in PCT / US2019 / 036010, when the spring member 2440a is made of a flat sheet of metal, mounted within the male terminal 2470, and connected to the female terminal assembly 800, and subjected to elevated temperatures, the spring member 440a exerts an outward spring thermal force S on the contact arms 2494a-2494h. TF, in part because the spring member 2440a attempts to return to the flat sheet. However, it should be understood that other methods of forming the spring member 2440a may be used, such as casting or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the spring member 2440a may not be integrally formed or formed as a whole, but may be formed from separate pieces that are welded together.

[0199] In addition, it should be understood that connector system 2000 is T4 / V4 / S3 / D2 / M2, where system 2000 meets and exceeds the following conditions: (i) T4 is exposure of system 100 to 150°C; (ii) V4 is severe vibration; (iii) S1 is sealing high-pressure spray; (iv) D2 is 200k mile durability; and (v) M2 is less than 45 Newtons to connect male connector assembly 2200 to female connector assembly 2600. In addition, it should be understood that the male terminal assembly 2430 and female terminal assembly 2800 disclosed in this application can be replaced by the male terminal assembly and female terminal assembly disclosed in PCT / US2018 / 019787 or PCT / US2019 / 36010. In addition, PCT / US2020 / 14484 discloses some of the connector derating.

[0200] Furthermore, it should be understood that alternative configurations for the connector system 2000 are possible. For example, any number of male terminal assemblies 2430 can be positioned within a single male housing assembly 2220. For example, the male housing assembly 2220 can be configured to contain a plurality (e.g., between 2-30, preferably between 2-8, and most preferably between 2-4) of male terminal assemblies 2430. The female connector assembly 2600 can be reconfigured to receive these multiple male terminal assemblies into a single female terminal assembly 2800. Alternatively, the female connector assembly 2600 can be reconfigured to include a plurality of female terminal assemblies 2800, each of which receives a single male terminal assembly 2430. Furthermore, it should be understood that the male terminal assembly 2430 can have any number of contact arms 2494 (e.g., between 2 and 100, preferably between 2 and 50, and most preferably between 2 and 8) and any number of spring arms 2452 (e.g., between 2 and 100, preferably between 2 and 50, and most preferably between 2 and 8). As discussed above, the number of contact arms 2494 may not be equal to the number of spring arms. For example, there may be more contact arms 2494 than spring arms 2452. Alternatively, there may be fewer contact arms 2494 than spring arms 2452.

[0201] Rather than bending the busbar 1000 in a plane 750, the two busbars 1000a, 1000b can be joined together to form a single busbar. This can be beneficial when the customer's application does not allow for the space required to have an in-plane bend 750. Here, the two busbars 1002, 1004 are joined together at a defined angle (e.g., 90 degrees) using a "densification weld." The densification weld is designed to create sufficient intermixed surface area, equivalent to 120% of the cross-sectional area of ​​the busbar 100. This helps ensure that this area does not become a current limiter and heat generator. Figures 67 to 72 In the exemplary embodiment shown in , this 90 degree weld is negligible, having a resistance 10% lower than a straight busbar of the same length 1000. This is extremely beneficial because a 90 degree bend cannot be achieved in a conventional busbar without creating a resistance range within the busbar.

[0202] When two busbars 1000 are welded together at a defined angle, the conductors 90 contained within each side of the busbars may have an overlapping, dovetailed, or interwoven arrangement. Figures 67 to 68 Two examples of such an arrangement are shown in FIG. Figure 67 Two busbars 1002, 1004 are shown, with one busbar 1002 having segments removed from two of the conductors 1090 and the other busbar 1004 having segments removed from three of the conductors 90. These removed segments are sized cooperatively to fit one another. Alternatively, Figure 68 Two busbars 1002, 1004 are shown, with two segments removed from the first busbar 1002 and three segments removed from the second busbar 1004. It should be understood that other overlapping, dovetailed, or interwoven arrangements are also contemplated by the present disclosure. Once the busbars are arranged, the designer can use Figures 69 to 70 The welding machine 789 shown in FIG. 7 is used to weld these busbars to each other. Figures 22C to 22E Combination fusion patterns that can be used by welding machine 789 are shown.

[0203] As an alternative to using the laser welder 850, the designer may have decided to use a resistance spot welder 901. The resistance spot welder 901 may include two manufacturing modes 902a and 902b, with the first manufacturing mode 902a being a prototype manufacturing mode and the second manufacturing mode 902b being a mass production manufacturing mode. In the first or prototype manufacturing mode 902a, the user controls the area of ​​the busbar 1000 to be welded by manually feeding the busbar 1000 into the machine and then activating the machine 901 using a foot pedal. Upon activation, the machine 901 forces the charged electrodes 909a and 909b into contact with the conductor 1090. This contact causes the electricity from the electrodes 909a and 909b to form at least a partially solidified region 1650. The designer may perform this contact procedure multiple times to form the fused section 1220 of the busbar 1000.

[0204] Alternatively, if the designer selects the second or batch production manufacturing mode 902b, the designer will need to select a design for the roller electrodes 906a, 906b. Figures 76 to 78 Examples of these electrode designs are shown in FIG. Specifically, the roller electrodes 906a, 906b may have a convex surface ( Figure 76 ) or may have a concave surface ( Figures 77 to 78 ). The raised surfaces will only contact the conductors 1090 of the busbar 1000 within these raised surfaces. This contact of these raised surfaces with the conductors 1090 will weld the busbar 1000 in these locations or areas. For example, Figure 76 The rollers shown in will form a pattern containing two sine waves. In contrast, if rollers 906a, 906b had concave extensions, these extensions would not contact busbar 1000 and the weld area would be the remaining surface of rollers 906a, 906b. For example, Figure 77 The rollers shown in FIG will weld all areas within the busbar 1000 except for the areas that will be contained within the oval area. It should be understood that the exemplary rollers 906a, 906b are examples only and are non-limiting.

[0205] Similar to that described above and in FIG1 to Figure 79 The busbar 1000 shown in FIG. Figure 79 A second embodiment of busbar 3000 is shown. For the sake of brevity, the above disclosure regarding busbar 1000 will not be repeated below, but it should be understood that similar numbers separated by 2000 in each embodiment represent similar structures. For example, the disclosure regarding fused section 1220 is also applicable to fused section 3220. Furthermore, it should be understood that the functionality of busbar 3000 is similar or equivalent to that disclosed regarding busbar 1000. The general features of this second embodiment 3000 are identified in step 110 and are Figure 14B and the label design 5 is shown. Specifically, Figure 14B and labeled Design 5 shows that the busbar designer has identified five fused segments 3220 and four unfused segments 5220 . Figure 79 , wherein four of the bends have only an in-plane 3750 aspect, while another bend has both an in-plane 3750 and an out-of-plane aspect 3760. Similar to busbar 1000, busbar 3000 includes a connector 4000 that is identical to connector 2000.

[0206] Similar to that described above and in FIG1 to Figure 79 The busbar 1000 shown in FIG. Figure 80 A third embodiment of busbar 5000 is shown. For the sake of brevity, the above disclosure regarding busbar 1000 will not be repeated below, but it should be understood that similar numbers separated by 4000 in each embodiment represent similar structures. For example, the disclosure regarding fused section 1220 is also applicable to fused section 5220. Furthermore, it should be understood that the functionality of busbar 5000 is similar or equivalent to that disclosed regarding busbar 1000. The general features of this third embodiment 5000 are identified in step 110 and are described in detail below. Figure 14B and the label design 5 is shown. Specifically, Figure 14B and labeled Design 5 shows that the busbar designer has identified five fused segments 5220 and four unfused segments 5220 . Figure 80 57. The bends of the fused segments 5220 are shown in FIG. 57, where four of the bends have only in-plane aspects 5750, while another bend has both in-plane 5750 and out-of-plane aspects 5760. Additionally, in this embodiment 5000, the extent of the unfused segments 5520 is curved. Similar to busbar 1000, busbar 5000 includes a connector 6000 that is identical to connector 2000.

[0207] Similar to that described above and in FIG1 to Figure 79 The busbar 1000 shown in FIG. Figure 81 A fourth embodiment of busbar 7000 is shown. For the sake of brevity, the above disclosure regarding busbar 1000 will not be repeated below, but it should be understood that similar numbers separated by 6000 in each embodiment represent similar structures. For example, the disclosure regarding fused section 1220 is also applicable to fused section 7220. Furthermore, it should be understood that the functionality of busbar 7000 is similar or equivalent to that disclosed regarding busbar 1000. The general features of this fourth embodiment 7000 are identified in step 110 and are described in detail below. Figure 14B and the label design 6. Specifically, Figure 14B and labeled Design 6 shows that the busbar designer has identified three fused segments 7220 and three unfused segments 7220 . Figure 81 7750 , wherein the three bends have only in-plane aspects 7750 . Similar to busbar 1000 , busbar 7000 includes connector 8000 that is identical to connector 2000 .

[0208] Similar to that described above and in FIG1 to Figure 79 The busbar 1000 shown in FIG. Figure 82 A fourth embodiment of busbar 9000 is shown. For the sake of brevity, the above disclosure regarding busbar 1000 will not be repeated below, but it should be understood that similar numerals separated by 8000 represent similar structures in each embodiment. For example, the disclosure regarding fused section 1220 is also applicable to fused section 9220. Furthermore, it should be understood that the functionality of busbar 9000 is similar or identical to that disclosed regarding busbar 1000. Unlike busbar 1000, busbar 9000 includes conventional bolt connectors 10,999.

[0209] C. Delivery and installation of busbars

[0210] Once the middle portion 1200 and end portions 1700 of the busbar 1000 are formed, there are a number of options for how the busbar 1000 is delivered and installed within an environment, application, system, product, component, or device. Specifically, Figure 51 Three different options 199a, 199b, and 199c are shown. The first option 199a is to ship the bus 1000 to the customer in a narrow and flat configuration and the customer bends the bus 1000 to form all desired bends. Once the bus 1000 incorporates the necessary bends, the bus 1000 can be installed in a system (e.g., a battery pack in a vehicle). The second option 199b is to bend the bus 1000 in-plane 1750 and then ship it to the customer. In this configuration, the bus 1000 does not include any bends in the Z direction and is therefore substantially flat. Once the customer receives the bus 1000, the customer can bend the bus 1000 to form an out-of-plane bend 1760. Once the bus 1000 incorporates the necessary bends, the bus 1000 can be installed in a system (e.g., a battery pack in a vehicle). Shipping busbar 1000 with either option 199a or option 199b reduces the likelihood of damage to busbar 1000. Additionally, the busbar's package size can be significantly reduced, thus saving significant amounts of money that would otherwise be spent on shipping costs. Finally, in option 199c, busbar 1000 can be shipped to the customer ready for installation, requiring the customer to perform additional bending.

[0211] To bend busbar 1000 into a desired configuration, busbar 1000 may have: (i) one or more in-plane bends 1750; (ii) one or more out-of-plane bends 1760; or (iii) a combination of one or more in-plane bends 1750 and one or more out-of-plane bends 1760. As shown and discussed above, in-plane bends 1750 are formed only within fused section 1220 of busbar 1000. This helps ensure that the individual conductors within busbar 1000 do not delaminate due to the bend. In other words, in-plane bends 1750 are not formed within unfused section 1520 of busbar 1000. In contrast, out-of-plane bends 1760 can be formed within either fused section 1220 or unfused section 1520. This is because out-of-plane bends 1760 do not result in the same stress being imposed on conductor 1090 as out-of-plane bends 1750 would impose on conductor 1090. Therefore, when the designer / manufacturer bends the busbar 1000 into its installed configuration, the designer / manufacturer must ensure that they bend the busbar 1000 in the appropriate segments 1220, 1520. Additionally, the busbar / manufacturer must be able to apply the appropriate amount of force to bend the busbar 1000 into the desired shape. In an illustrative and non-limiting example, the pressure required to bend the unfused segment 1520 of the busbar may require approximately 250 pounds of force. To bend the fused segment 1220 of the busbar 1000, the designer will need to apply a greater force than would be required to bend an unfused segment, but less than the force required to bend a fully solidified busbar. For example, the force required to bend the fused segment 1220 may be between 250 and 500 pounds.

[0212] To form these bends, the designer / manufacturer can use Figures 52 to 55B In particular, Figures 780a, 780b show a bending machine for bending the prototype busbar 1000, while Figures 780a, 780b show a bending machine for bending the prototype busbar 1000. Figures 54 to 55B A bending machine for bending a busbar 1000 manufactured using mass-produced components is shown. The prototype bending machine 780a includes three spools 782a, 782b, 782c, whose sides are configured to completely enclose the busbar 1000 when bending. The middle spool 782b is attached to an arm 784, which can be rotated downward to apply downward pressure on the busbar 1000 based on the positional relationship of the two end spools 782a, 782c. In other words, the middle spool 782b acts as a mandrel to bend the busbar 1000 in the plane 1750. The mass-production machine 780c automates the functions of the prototype bending machines 780a, 780b. Specifically, Figure 55A and 55B17. This mass production machine 780c is shown to simultaneously create in-plane bends 1750 and out-of-plane bends 1760 in busbar 1000. It should be understood that these are merely examples of machines 780a-780c that may be used to bend busbar 1000. For example, some out-of-plane bends 1760 may not be bent by a machine, but rather may be bent by hand.

[0213] Figures 83 to 84 A motor vehicle environment M is shown including a power distribution system 11000 that includes a number of components such as a charger, a battery pack assembly 11002, a DC-DC converter, and an electric motor. Figures 83 to 84 , the battery assembly 11004 has a skateboard configuration, wherein the battery assembly 11002 has a plurality (e.g., 36) of battery modules 11006 that, when installed, are arranged in a substantially linear configuration positioned at or below the level of the vehicle axles and positioned beneath a substantial portion of the motor vehicle body 11008. The battery modules 11006 are formed from a plurality (e.g., 12) of cells that are coupled to one another to form a positive terminal 11010 and a negative terminal 11012 for each battery module 11006. The positive terminals 11010 of the battery modules 11006 are coupled to one another (e.g., in parallel and in series) using busbars 1000, 3000, 5000, 7000, 9000 to create a battery pack 11002 that provides a suitable voltage level for operation of the motor vehicle M. Like the positive terminal 11010, the negative terminal 11012 is similarly coupled together using busbars 1000, 3000, 5000, 7000, 9000. It should be understood that the busbars 1000, 3000, 5000, 7000, 9000 can be used in components contained within the motor vehicle environment M and external to the battery pack assembly 11002. In addition, the busbars 1000, 3000, 5000, 7000 of the present invention comply with PCTR, which not only reduces the height requirement of the busbar but also simplifies installation.

[0214] It may be desirable to gather information gained from the fabrication and bending of busbar 1000, which has been fabricated from engineering model 100. This information can then be fed back into the overall computer system to more accurately convert non-engineering models 68a-68h into engineering model 100 and test engineering model 100. For example, the information that can be fed back into the computer system may include: (i) whether the fusing method also results in fully solidified regions; (ii) whether the fusing method does not result in partially solidified regions extending to the desired depth; (iii) the bending force required to bend fused section 1220; (iv) the electrical properties of the fused section; (v) whether fused section 1220 delaminates during bending; or (vi) other relevant information. The computer system can take this information and modify the FE model used in testing. Because the FE model accurately predicts how busbar 1000 will operate when manufactured, designers can use the FE model to help convert non-engineering models 68a-68h into engineering model 100. It should be understood that the information fed back into the computer system can be fitted and / or analyzed using a learning algorithm or neural network. This analysis can then be used to modify the FE model to improve its accuracy, which in turn will allow for a more accurate creation of the engineering model 100 , which will result in a cheaper, better performing, and more durable busbar 1000 .

[0215] Materials and Disclosures Incorporated by Reference

[0216] PCT Application Nos. PCT / US2020 / 49870, PCT / US2020 / 14484, PCT / US2020 / 13757, PCT / US2019 / 36127, PCT / US2019 / 36070, PCT / US2019 / 36010 and PCT / US2018 / 019787, U.S. Patent Application No. 16 / 194891 and U.S. Provisional Applications 62 / 897658, 62 / 897962, 62 / 897962, 62 / 988972, 63 / 051639, 63 / 058061, 29 / 749790 and 29 / 749813, each of which is incorporated herein by reference in its entirety and made a part hereof.

[0217] SAE specifications, including: J1742_201003, entitled "Connections for High Voltage On-Board Vehicle Electrical Wiring Harnesses-Test Methods and General Performance Requirements", last revised in March 2010, each of which is fully incorporated herein by reference and made a part hereof.

[0218] ASTM specifications, including: (i) D4935-18, entitled “Standard Test Method for Measuring the Electromagnetic Shielding Effectiveness of Planar Materials”; and (ii) ASTM D257, entitled “Standard Test Methods for DC Resistance or Conductance of Insulating Materials,” each of which is incorporated herein by reference in its entirety and made a part hereof.

[0219] American National Standards Institute and / or EOS / ESD Association specifications, including: ANSI / ESD STM11.11 Measurement of Surface Resistivity of Static Dissipative Planar Materials, each of which is incorporated herein by reference in its entirety and made a part hereof.

[0220] DIN specifications, including Connectors for Electronic Equipment - Tests and Measurements - Part 5-2: Current-Carrying Capacity Test; Test 5b: Current Temperature Derating (IEC 60512-5-2:2002), each of which is hereby incorporated by reference in its entirety and made a part hereof.

[0221] USCAR specifications, including: (i) SAE / USCAR-2, Revision 6, last revised February 2013, ISBN: 978-0-7680-7998-2; (ii) SAE / USCAR-12, Revision 5, last revised August 2017, ISBN: 978-0-7680-8446-7; (iii) SAE / USCAR-21, Revision 3, last revised December 2014; (iv) SAE / USCAR-25, Revision 3, revised March 2016, ISBN: 978-0-7680-8319-4; (v) SAE / USCAR-37, revised August 2008, ISBN: 978-0-7680-2098-4; (vi) SAE / USCAR-38, revised May 2016, ISBN: 978-0-7680-8350-7, each of which is incorporated herein by reference in its entirety and made a part hereof.

[0222] Other standards, including Federal Test Standards 101C and 4046, each of which is fully incorporated by reference and made a part hereof.

[0223] Industrial Applicability

[0224] The busbar 1000 of the present invention described herein has many advantages over other busbar systems currently in existence. Some of these advantages include: (i) using less material; (ii) being lighter in weight; (iii) providing an adequate current path, which allows the busbar to carry more current without significantly increasing the temperature; (iv) being able to be shipped in a substantially flat configuration, which reduces shipping costs and reduces the chance that the busbar may deform; (v) being available in either a bolted or boltless configuration, wherein the boltless configuration reduces the labor costs associated with installation; (vi) not requiring special molds or manufacturing techniques to enable the busbar 1000 to be custom-fitted to a specific application; (vii) not requiring a combination of multiple different materials, which also increases the amount of current that the busbar 1000 can handle without significantly increasing the temperature; (viii) having a low-profile configuration, which allows designers to reduce the height of the battery pack; and (ix) being able to form complex geometries at or near where the busbar is mounted.

[0225] While the foregoing describes what is considered to be the best mode and / or other examples, it should be understood that various modifications may be made therein, and that the subject matter disclosed herein may be implemented in a variety of forms and embodiments, and that the teachings may be applied to a variety of applications, only some of which are described herein. For example, within intermediate portion 1200, busbar 1000 may not include unfused segments 1520 and may include only fused segments 1220. The appended claims are intended to claim any and all applications, modifications, and variations that fall within the true scope of the present teachings. Other implementations are also contemplated.

[0226] While a few specific implementations have been illustrated and described, many modifications are contemplated without departing significantly from the spirit of the present disclosure; and the scope of protection is limited only by the scope of the appended claims. Headings and subheadings, if any, are used for convenience only and are not limiting. The word exemplary is used to mean serving as an example or illustration. To the extent that the terms "including," "having," and the like are used, such terms are intended to be inclusive in a manner similar to the term "comprising" as interpreted when used as a transitional word in the claims. Relational terms (such as first and second) may be used to distinguish one entity or act from another without necessarily requiring or implying any actual such relationship or order between such entities or acts.

[0227] Phrases such as aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the present disclosure, other variations thereof, and similar variations thereof are used for convenience and do not imply that the disclosure associated with such phrases is essential to the present technology or that such disclosure applies to all configurations of the present technology. Disclosure associated with such phrases may apply to all configurations or one or more configurations. Disclosure associated with such phrases may provide one or more examples. A phrase such as aspect or some aspects may refer to one or more aspects and vice versa, and similarly applies to the other aforementioned phrases.

[0228] In view of the foregoing description, many modifications to the present disclosure will be apparent to those skilled in the art. Preferred embodiments of the present disclosure are described herein, including the best mode known to the inventors for carrying out the present disclosure. It should be understood that the illustrated embodiments are exemplary only and should not be considered as limiting the scope of the present disclosure.

Claims

1. A busbar for electrically connecting components in a device, the busbar comprising: a plurality of conductors arranged to provide two opposing end portions and a middle portion, wherein each of the conductors has a plurality of middle extents traversing the middle portion, and wherein the intermediate portion includes a fused section having: (i) a partially solidified region wherein a substantial portion of the intermediate extent of the conductor is fused together to form a partially solidified area, the partially solidified area providing a single consolidated conductor; and (ii) an unsolidified region wherein none of the intermediate extent of the conductor is fused together, wherein the intermediate portion further comprises an unfused segment, wherein none of the intermediate extent of the conductor is fused together, and The fused section further includes a completely solidified edge region. 2 . The busbar of claim 1 , wherein the plurality of conductors are arranged in a vertical stack, the vertical stack defining a fused segment height, and wherein a height of the partially solidified region is less than the fused segment height.

3. The busbar of claim 2, wherein the uncured area is located: (a) between the height of the fused section and the height of the partially cured area; and (b) in the partially cured area.

4. The busbar of claim 1 , wherein the length, width, and height of the fused section of the intermediate portion collectively define a fused section volume, and wherein the fused section includes a plurality of additional partially solidified regions disposed within the fused section volume.

5. The busbar of claim 1, wherein the fused section further comprises a plurality of additional unsolidified regions, the plurality of additional unsolidified regions occupying a majority of the volume of the fused section and the partially solidified regions occupying a minority of the volume of the fused section.

6. The busbar of claim 1, the intermediate portion further comprising an unfused section having a stiffness less than that of the partially solidified region, and wherein the partially solidified region promotes in-plane bending of the fused section of the intermediate portion.

7. The busbar of claim 1, wherein the stiffness of the partially solidified region: (a) promotes in-plane bending of the fused section of the intermediate portion; and (b) maintains the in-plane bending of the fused section over time.

8. The busbar according to any one of claims 1 to 7, wherein in the fully solidified edge region, the mid-range of the conductor is all fused together to provide a single consolidated conductor.

9. The busbar of claim 8, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack defining a fused segment height, and wherein a height of the fully solidified region is greater than or equal to the fused segment height.

10. The busbar of claim 8, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and wherein the fully solidified region extends between the uppermost conductor and the lowermost conductor.

11. The busbar of claim 8, wherein the fully cured edge region prevents the plurality of conductors from delaminating from one another when the middle portion of the busbar is bent in-plane.

12. The busbar of claim 8, wherein the intermediate portion includes an inner weld boundary between the fully solidified edge region and the unsolidified region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary is less than 5 mm.

13. The busbar of claim 8, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary varies along a height of the busbar.

14. The busbar of claim 8, wherein the fully solidified edge region has undergone a full penetration welding process.

15. The busbar of claim 14, wherein the middle portion of the busbar comprises an upper edge and a lower edge; and in, The upper edge and the lower edge are rounded by applying the full penetration welding process.

16. The busbar of claim 14, wherein a laser is used in the full penetration welding process.

17. The busbar of claim 16, wherein the plurality of conductors are arranged in a vertical stack having an uppermost conductor and a lowermost conductor defining a fused section height extending therebetween, and wherein The laser follows a circular pattern with an amplitude smaller than the height of the fused section.

18. The busbar of claim 8, wherein the fully solidified edge region has undergone a cold forming process.

19. The busbar according to any one of claims 1 to 7, wherein the fully cured edge region is formed by applying a laser to the edge of the middle portion of the busbar.

20. The busbar of claim 19, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and The laser follows a circular pattern with an amplitude less than the height of the fused section.

21. The busbar according to any one of claims 1 to 7, wherein at least one of the two opposing end portions comprises a fully cured region, wherein: All conductors are fused together to form a single consolidated conductor.

22. The busbar of claim 21, wherein the fully cured region is configured to engage a connector for securing the busbar to the component in the device.

23. The busbar of claim 21 , wherein the fully cured region is formed by applying a laser to: (a) an upper surface of an uppermost conductor of at least one end portion of the busbar; and (b) a lower surface of a lowermost conductor of at least one end portion of the busbar.

24. The busbar of claim 21, wherein the fully solidified region is formed by applying a laser, wherein the laser follows a combined pattern including a top fusion pattern and a bottom fusion pattern.

25. The busbar of claim 24, wherein the combined pattern is concentric rectangles.

26. The busbar of claim 24, wherein the combination pattern is determined based on a type of connector to be coupled to the at least one end portion.

27. The busbar of claim 25, wherein the fully cured region is configured to engage a connector for securing the busbar to the component in the device, wherein the connector type is a male terminal assembly with an internal spring member.

28. The busbar of claim 21, wherein the surface area of ​​the fully cured region is at least equal to 120% of the cross-sectional area of ​​the at least one end portion.

29. The busbar according to any one of claims 1 to 7, wherein the fused section is a first fused section, the partially solidified region is a first partially solidified region, the partially solidified area is a first partially solidified area, and the unsolidified area is a first unsolidified area; and The middle portion further comprises a second fusion section, which comprises: (i) a second partially cured region wherein a majority of the mid-extent of the conductor is fused together to form a second partially cured area, the second partially cured area providing a single consolidated conductor, and (ii) a second uncured area wherein none of the mid-extent of the conductor is fused together.

30. The busbar of claim 29, wherein the first fused section is configured to have a first in-plane bend radius and the second fused section is configured to have a second in-plane bend radius, wherein the first in-plane bend radius is smaller than the second in-plane bend radius.

31. The busbar of claim 29, wherein the first fused segment has a length, a width, and a height that together define a first fused segment volume, and the second fused segment has a length, a width, and a height that together define a second fused segment volume; and The first partially solidified region occupies a first percentage of the volume of the first fused section and the second partially solidified region occupies a second percentage of the volume of the second fused section, and wherein the first percentage is less than the second percentage.

32. The busbar of claim 29, wherein the first fused section has a first stiffness that is less than a second stiffness of the second fused section.

33. The busbar of claim 29, wherein the first partially solidified region and the second partially solidified region are formed by applying a laser, wherein the laser follows a first pattern in the first fused section and a second pattern in the second fused section.

34. The busbar of claim 33, wherein the first pattern is a line waveform and the second pattern is a triangle waveform.

35. The busbar of claim 33, wherein the first pattern has a first waveform frequency and the second pattern has a second waveform frequency greater than the first waveform frequency.

36. The busbar of any one of claims 1-7, wherein the fused section is a first fused section, the partially solidified region is a first partially solidified region, the partially solidified area is a first partially solidified area, and the unsolidified area is a first unsolidified area; and The middle portion further comprises a second fusion section, which comprises: (i) a fully cured region wherein the mid-extents of the conductors are all fused together to form a fully cured edge region, the fully cured edge region providing a single consolidated conductor, and (ii) a second uncured region wherein none of the mid-extents of the conductors are fused together.

37. The busbar of claim 36, wherein the first fused section is configured to have a first in-plane bend radius and the second fused section is configured to have a second in-plane bend radius, wherein the first in-plane bend radius is greater than the second in-plane bend radius.

38. The busbar of claim 36, wherein the first fused segment has a length, a width, and a height that together define a first fused segment volume, and the second fused segment has a length, a width, and a height that together define a second fused segment volume; and wherein the first partially solidified region occupies a first percentage of the volume of the first fusion segment and the fully solidified edge region occupies a second percentage of the volume of the second fusion segment, and wherein the first percentage is greater than the second percentage.

39. The busbar of claim 36, wherein the first fused section has a first stiffness greater than a second stiffness of the second fused section.

40. The busbar of claim 36, wherein the first and second fused segments are formed by applying a laser, wherein the laser follows a first pattern in the first fused segment and a second pattern in the second fused segment.

41. The busbar of claim 40, wherein the first pattern is a line waveform and the second pattern is a circular waveform.

42. The busbar of claim 41, wherein the first pattern is a triangular waveform and the second pattern is a circular waveform.

43. The busbar of claim 36, wherein the first partially cured region is formed using a laser and the fully cured edge region is formed using a cold forming process.

44. The busbar of any one of claims 1-7, wherein the partially cured region comprises an inner cured region that is denser than an outer cured region, wherein the outer cured region is located adjacent to the uncured region.

45. The busbar of any one of claims 1-7, wherein the partially solidified region has undergone a partial penetration welding process.

46. ​​The busbar of claim 45, wherein a laser is used in the partial penetration welding process.

47. The busbar of any one of claims 1-7, wherein the middle portion of the busbar has stiffness and the partially cured region occupies a first volume; and in, Increasing the volume of the partially cured region increases the stiffness of the middle portion of the busbar.

48. The busbar of any one of claims 1-7, wherein the busbar is used to interconnect battery modules in a battery pack.

49. The busbar of any one of claims 1-7, wherein the busbar is used to interconnect electrical components and power sources in a power distribution system.

50. A busbar for electrically connecting components in a device, the busbar comprising: a plurality of conductors arranged to provide two opposing end portions and a middle portion, wherein each of the conductors has a plurality of middle extents traversing the middle portion, the middle portion comprising: unfused segments, wherein the mid-range of the conductor is not fused together to form a single consolidated conductor, and a fused section comprising: (i) a partially cured region wherein a majority of the mid-extent of the conductor is fused together to form a partially cured area, the partially cured area providing a single consolidated conductor; (ii) a fully cured region wherein all of the mid-extent of the conductor is fused together to form a fully cured area, the fully cured area providing a single consolidated conductor; and (iii) an uncured region wherein none of the mid-extent of the conductor is fused together, wherein the partially solidified region promotes in-plane bending of the fused section of the intermediate portion.

51. The busbar of claim 50, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack defining a fused section height, and wherein a height of the partially solidified region is less than the fused section height.

52. The busbar of claim 51, wherein an uncured area is located (a) between the height of the fused section and the height of the partially cured region, and (b) within the partially cured region.

53. The busbar of claim 50, wherein the intermediate portion further comprises an unfused section, wherein none of the intermediate extents of the conductors are fused together.

54. The busbar of claim 50, wherein the length, width, and height of the fused section of the intermediate portion collectively define a fused section volume, and wherein the fused section comprises a plurality of additional partially solidified regions disposed within the fused section volume.

55. The busbar of claim 50, wherein the fused section further comprises a plurality of additional unsolidified regions, the plurality of additional unsolidified regions occupying a majority of the volume of the fused section and the partially solidified regions occupying a minority of the volume of the fused section.

56. The busbar of claim 50, wherein the intermediate portion further comprises an unfused section, wherein the unfused section has a stiffness less than a stiffness of the partially solidified region.

57. The busbar of claim 51 , wherein the stiffness of the partially solidified region: (a) promotes in-plane bending of the fused section of the intermediate portion; and (b) maintains the in-plane bending of the fused section over time.

58. The busbar of claim 50, wherein the fully solidified region has undergone a full penetration welding process.

59. The busbar of claim 58, wherein a laser is used in the full penetration welding process.

60. The busbar of claim 50, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack defining a fused segment height, and wherein a height of the fully solidified region is greater than or equal to the fused segment height.

61. The busbar of claim 50, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and wherein the fully solidified region extends between the uppermost conductor and the lowermost conductor.

62. The busbar of claim 50, wherein the fully cured region is a fully cured edge region.

63. The busbar of claim 62, wherein the fully cured edge region prevents the plurality of conductors from delaminating from one another when the intermediate portion of the busbar is bent in-plane.

64. The busbar of claim 62, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary is less than 5 mm.

65. The busbar of claim 62, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary varies along a height of the busbar.

66. The busbar of claim 62, wherein the fully solidified edge region has undergone a full penetration welding process.

67. The busbar of claim 66, wherein the middle portion of the busbar comprises an upper edge and a lower edge; and in, The upper edge and the lower edge are rounded by applying the full penetration welding process.

68. The busbar of claim 66, wherein a laser is used in the full penetration welding process.

69. The busbar of claim 68, wherein the plurality of conductors are arranged in a vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and wherein The laser follows a circular pattern with an amplitude smaller than the height of the fused section.

70. The busbar of claim 62, wherein the fully solidified edge region has undergone a cold forming process.

71. The busbar according to any one of claims 50 to 70, wherein at least one of the two opposing end portions comprises a fully cured region, wherein: All conductors are fused together to form a single consolidated conductor.

72. The busbar of claim 71, wherein the fully cured region is configured to engage a connector for securing the busbar to the component in the device.

73. The busbar of claim 72, wherein the connector includes a male terminal assembly having an internal spring member.

74. A busbar according to claim 71, wherein the fully cured area is formed by applying laser to both: (a) the upper surface of the uppermost conductor of at least one end portion of the busbar; and (b) the lower surface of the lowermost conductor of at least one end portion of the busbar.

75. The busbar of claim 71, wherein the surface area of ​​the fully cured region is at least equal to 120% of the cross-sectional area of ​​the at least one end portion.

76. The busbar of claim 71, wherein the fully solidified region is formed by applying a laser, wherein the laser follows a combined pattern comprising a top fusion pattern and a bottom fusion pattern.

77. The busbar of claim 76, wherein the fully cured region is configured to engage with a connector for securing the busbar to the component in the device, wherein the combination pattern is determined based on a type of connector to be coupled to the at least one end portion.

78. The busbar of claim 76, wherein the combined pattern is concentric rectangles.

79. The busbar of any one of claims 50-70, wherein the fused section is a first fused section, the partially solidified region is a first partially solidified region, the partially solidified area is a first partially solidified area, and the unsolidified area is a first unsolidified area; and The middle portion further comprises a second fusion section, which comprises: (i) a second partially cured region wherein a majority of the mid-extent of the conductor is fused together to form a second partially cured area, the second partially cured area providing a single consolidated conductor, and (ii) a second uncured area wherein none of the mid-extent of the conductor is fused together.

80. The busbar of claim 79, wherein the first fused section is configured to have a first in-plane bend radius and the second fused section is configured to have a second in-plane bend radius, wherein the first in-plane bend radius is smaller than the second in-plane bend radius.

81. The busbar of claim 79, wherein the first fused segment has a length, a width, and a height that together define a first fused segment volume, and the second fused segment has a length, a width, and a height that together define a second fused segment volume; and The first partially solidified region occupies a first percentage of the volume of the first fused section and the second partially solidified region occupies a second percentage of the volume of the second fused section, and wherein the first percentage is less than the second percentage.

82. The busbar of claim 79, wherein the first fused section has a first stiffness that is less than a second stiffness of the second fused section.

83. The busbar of claim 79, wherein the first partially solidified region and the second partially solidified region are formed by applying a laser, wherein the laser follows a first pattern in the first fused section and a second pattern in the second fused section.

84. The busbar of claim 83, wherein the first pattern is a line waveform and the second pattern is a triangle waveform.

85. The busbar of claim 83, wherein the first pattern has a first waveform frequency and the second pattern has a second waveform frequency greater than the first waveform frequency.

86. The busbar of any one of claims 50-70, wherein the fused section is a first fused section, the partially solidified region is a first partially solidified region, the partially solidified area is a first partially solidified area, and the unsolidified area is a first unsolidified area; and The middle portion further comprises a second fusion section, which comprises: (i) a second fully cured region wherein the mid-extents of the conductors are all fused together to form a second fully cured edge region, the second fully cured edge region providing a single consolidated conductor, and (ii) a second uncured region wherein none of the mid-extents of the conductors are fused together.

87. The busbar of claim 86, wherein the first fused section is configured to have a first in-plane bend radius and the second fused section is configured to have a second in-plane bend radius, wherein the first in-plane bend radius is greater than the second in-plane bend radius.

88. The busbar of claim 86, wherein the first fused segment has a length, a width, and a height that together define a first fused segment volume, and the second fused segment has a length, a width, and a height that together define a second fused segment volume; and The first partially solidified region occupies a first percentage of the volume of the first fusion segment and the second fully solidified edge region occupies a second percentage of the volume of the second fusion segment, and the first percentage is greater than the second percentage.

89. The busbar of claim 86, wherein the first fused segment has a first stiffness greater than a second stiffness of the second fused segment.

90. The busbar of claim 86, wherein the first and second fused segments are formed by applying a laser, wherein the laser follows a first pattern in the first fused segment and a second pattern in the second fused segment.

91. The busbar of claim 90, wherein the first pattern is a line waveform and the second pattern is a circular waveform.

92. The busbar of claim 91, wherein the first pattern is a triangular waveform and the second pattern is a circular waveform.

93. The busbar of claim 86, wherein the first partially solidified region is formed using a laser and the second fully solidified edge region is formed using a cold forming process.

94. The busbar of any one of claims 50-70, wherein the partially cured region comprises an inner cured region that is denser than an outer cured region, wherein the outer cured region is located adjacent to the uncured region.

95. The busbar of any one of claims 50-70, wherein the partially solidified region has undergone a partial penetration welding process.

96. The busbar of claim 95, wherein a laser is used in the partial penetration welding process.

97. The busbar of any one of claims 50-70, wherein the busbar is used to interconnect battery modules in a battery pack.

98. The busbar of any one of claims 50-70, wherein the busbar is used to interconnect electrical components and power sources in a power distribution system.

99. A busbar for electrically connecting components in a device, the busbar comprising: a plurality of conductors arranged to provide two opposing end portions and a middle portion, wherein each of the conductors has a plurality of middle extents traversing the middle portion, and The middle part includes: a first fused segment having: (i) a first partially solidified region wherein a majority of the mid-extent of the conductor is fused together to form a first partially solidified area, the first partially solidified area providing a single consolidated conductor; and (ii) a first unsolidified region wherein none of the mid-extent of the conductor is fused together; and a second fused section having: (i) a second partially solidified region wherein a majority of the mid-extent of the conductor is fused together to form a second partially solidified area, the second partially solidified area providing a single consolidated conductor; and (ii) a second unsolidified area wherein none of the mid-extent of the conductor is fused together.

100. The busbar of claim 99, wherein the first fused section is configured to have a first in-plane bend radius and the second fused section is configured to have a second in-plane bend radius, wherein the first in-plane bend radius is smaller than the second in-plane bend radius.

101. The busbar of claim 99, wherein the first fused segment has a length, a width, and a height that together define a first fused segment volume, and the second fused segment has a length, a width, and a height that together define a second fused segment volume; and The first partially solidified region occupies a first percentage of the volume of the first fused section and the second partially solidified region occupies a second percentage of the volume of the second fused section, and wherein the first percentage is less than the second percentage.

102. The busbar of claim 99, wherein the first fused segment has a first stiffness that is less than a second stiffness of the second fused segment.

103. The busbar of claim 99, wherein the first partially solidified region and the second partially solidified region are formed by applying a laser, wherein the laser follows a first pattern in the first fused segment and a second pattern in the second fused segment.

104. The busbar of claim 103, wherein the first pattern is a line waveform and the second pattern is a triangle waveform.

105. The busbar of claim 103, wherein the first pattern has a first waveform frequency and the second pattern has a second waveform frequency greater than the first waveform frequency.

106. The busbar according to any one of claims 99 to 105, wherein at least one of the two opposing end portions comprises a fully cured region, wherein: All conductors are fused together to form a single consolidated conductor.

107. The busbar of claim 106, wherein the fully cured region is configured to engage a connector for securing the busbar to the component in the device.

108. The busbar of claim 107, wherein the connector includes a male terminal assembly having an internal spring member.

109. A busbar according to claim 106, wherein the fully cured area is formed by applying a laser to both: (a) the upper surface of the uppermost conductor of at least one end portion of the busbar; and (b) the lower surface of the lowermost conductor of at least one end portion of the busbar.

110. The busbar of claim 106, wherein the surface area of ​​the fully cured region is at least equal to 120% of the cross-sectional area of ​​the at least one end portion.

111. The busbar of claim 106, wherein the fully solidified region is formed by applying a laser, wherein the laser follows a combined pattern comprising a top fusion pattern and a bottom fusion pattern.

112. The busbar of claim 111, wherein the fully cured region is configured to engage with a connector for securing the busbar to the component in the device, wherein the combination pattern is determined based on a type of connector to be coupled to the at least one end portion.

113. The busbar of claim 111, wherein the combined pattern is concentric rectangles.

114. The busbar of any one of claims 99-105, wherein the first fused section or the second fused section of the intermediate portion further comprises a fully solidified region wherein the intermediate extent of the conductor is all fused together to provide a single consolidated conductor.

115. The busbar of claim 114, wherein the fully solidified region has undergone a full penetration welding process.

116. The busbar of claim 115, wherein a laser is used in the full penetration welding process.

117. The busbar of claim 114, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack defining a fused segment height, and wherein a height of the fully solidified region is greater than or equal to the fused segment height.

118. The busbar of claim 114, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fusion section height extending therebetween, and wherein the fully solidified region extends between the uppermost conductor and the lowermost conductor.

119. The busbar of claim 114, wherein the fully cured region is a fully cured edge region.

120. The busbar of claim 119, wherein the fully cured edge region prevents the plurality of conductors from delaminating from one another when the intermediate portion of the busbar is bent in-plane.

121. The busbar of claim 119, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary is less than 5 mm.

122. The busbar of claim 119, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary varies along a height of the busbar.

123. The busbar of claim 119, wherein the fully solidified edge region has undergone a full penetration welding process.

124. The busbar of claim 123, wherein the middle portion of the busbar comprises an upper edge and a lower edge; and in, The upper edge and the lower edge are rounded by applying the full penetration welding process.

125. The busbar of claim 123, wherein a laser is used in the full penetration welding process.

126. The busbar of claim 125, wherein the plurality of conductors are arranged in a vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and wherein The laser follows a circular pattern with an amplitude smaller than the height of the fused section.

127. The busbar of claim 119, wherein the fully solidified edge region has undergone a cold forming process.

128. The busbar of any one of claims 99-105, wherein the first fused segment or the second fused segment further comprises a fully solidified edge region.

129. The busbar of claim 128, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary is less than 5 mm.

130. The busbar of claim 128, wherein the fully cured edge region is formed by applying a laser to an edge of the middle portion of the busbar.

131. The busbar of claim 130, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and The laser follows a circular pattern with an amplitude less than the height of the fused section.

132. The busbar of claim 128, wherein the fully solidified edge region has undergone a cold forming process.

133. A busbar for electrically connecting components in a device, the busbar comprising: a plurality of conductors arranged to provide two opposing end portions and a middle portion, wherein each of the conductors has a plurality of middle extents traversing the middle portion, and The middle part includes: a first fused segment having: (i) a first partially solidified region wherein a majority of the mid-extent of the conductor is fused together to form a first partially solidified area, the first partially solidified area providing a single consolidated conductor; and (ii) a first unsolidified region wherein none of the mid-extent of the conductor is fused together; and A second fused section, wherein the second fused section has: (i) a fully solidified region wherein the mid-range of the conductors are all fused together to form a fully solidified edge region, the second partially solidified region providing a single consolidated conductor; and (ii) a second unsolidified region wherein none of the mid-ranges of the conductors are fused together.

134. The busbar of claim 133, wherein the first fused section is configured to have a first in-plane bend radius and the second fused section is configured to have a second in-plane bend radius, wherein the first in-plane bend radius is greater than the second in-plane bend radius.

135. The busbar of claim 133, wherein the first fused segment has a length, width, and height that together define a first fused segment volume, and the second fused segment has a length, width, and height that together define a second fused segment volume; and wherein the first partially solidified region occupies a first percentage of the volume of the first fusion segment and the fully solidified edge region occupies a second percentage of the volume of the second fusion segment, and wherein the first percentage is greater than the second percentage.

136. The busbar of claim 133, wherein the first fused segment has a first stiffness greater than a second stiffness of the second fused segment.

137. The busbar of claim 133, wherein the first partially solidified region and the second partially solidified region are formed by applying a laser, wherein the laser follows a first pattern in the first fused segment and a second pattern in the second fused segment.

138. The busbar of claim 137, wherein the first pattern is a line waveform and the second pattern is a circular waveform.

139. The busbar of claim 138, wherein the first pattern is a triangular waveform and the second pattern is a circular waveform.

140. The busbar of claim 133, wherein the first partially cured region is formed using a laser and the fully cured edge region is formed using a cold forming process.

141. The busbar of any one of claims 133-140, wherein at least one of the two opposing end portions comprises a fully cured region, wherein: All conductors are fused together to form a single consolidated conductor.

142. The busbar of claim 141, wherein the fully cured region is configured to engage a connector for securing the busbar to the component in the device.

143. The busbar of claim 142, wherein the connector comprises a male terminal assembly having an internal spring member.

144. A busbar according to claim 141, wherein the fully cured area is formed by applying a laser to both: (a) the upper surface of the uppermost conductor of at least one end portion of the busbar; and (b) the lower surface of the lowermost conductor of at least one end portion of the busbar.

145. The busbar of claim 141, wherein the surface area of ​​the fully cured region is at least equal to 120% of the cross-sectional area of ​​the at least one end portion.

146. The busbar of claim 141, wherein the fully solidified region is formed by applying a laser, wherein the laser follows a combined pattern comprising a top fusion pattern and a bottom fusion pattern.

147. The busbar of claim 146, wherein the fully cured region is configured to engage with a connector for securing the busbar to the component in the device, wherein the combination pattern is determined based on the type of connector to be coupled to the at least one end portion.

148. The busbar of claim 146, wherein the combined pattern is concentric rectangles.

149. The busbar of any one of claims 133-140, wherein the fully solidified region has undergone a full penetration welding process.

150. The busbar of claim 149, wherein a laser is used in the full penetration welding process.

151. The busbar of any one of claims 133-140, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack defining a fused segment height, and wherein a height of the fully solidified region is greater than or equal to the fused segment height.

152. A busbar according to any one of claims 133-140, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fusion section height extending therebetween, and wherein the fully solidified region extends between the uppermost conductor and the lowermost conductor.

153. The busbar of any one of claims 133-140, wherein the fully cured region is a fully cured edge region.

154. The busbar of claim 153, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary is less than 5 mm.

155. The busbar of claim 153, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary varies along a height of the busbar.

156. The busbar of claim 153, wherein the fully solidified edge region has undergone a full penetration welding process.

157. The busbar of claim 156, wherein the middle portion of the busbar comprises an upper edge and a lower edge; and in, The upper edge and the lower edge are rounded by applying the full penetration welding process.

158. The busbar of claim 156, wherein a laser is used in the full penetration welding process.

159. The busbar of claim 158, wherein the plurality of conductors are arranged in a vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and wherein The laser follows a circular pattern with an amplitude smaller than the height of the fused section.

160. The busbar of claim 156, wherein the fully solidified edge region has undergone a cold forming process.

161. The busbar of any one of claims 133-140, wherein the intermediate portion includes an inner weld boundary between the fully solidified edge region and the unsolidified region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary is less than 5 mm.

162. The busbar of any one of claims 133-140, wherein the fully cured edge region is formed by applying a laser to the edge of the middle portion of the busbar.

163. The busbar of claim 162, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and The laser follows a circular pattern with an amplitude less than the height of the fused section.

164. The busbar of any one of claims 133-140, wherein the fully solidified edge region has undergone a cold forming process.

165. A busbar for electrically connecting components in a device, the busbar comprising: a plurality of conductors arranged to provide two opposing end portions and a middle portion extending between the opposing end portions, wherein each conductor of the plurality of conductors traverses the middle portion; as well as The middle part includes: Unfused segments, where no conductors are fused together, and A fused section comprising: (i) a fully solidified edge region wherein all of the conductors are fused together at their side edges to form a single consolidated conductor; and (ii) an unsolidified region wherein none of the conductors are fused together.

166. A busbar for electrically connecting components in a device, the busbar comprising: a plurality of conductors arranged to provide two opposing end portions and a middle portion extending between the opposing end portions, wherein each conductor of the plurality of conductors traverses the middle portion; as well as The middle part includes: a first fused section having: (i) a first unfused section in which no conductors are fused together, and (ii) a first fused section comprising (a) a first fully solidified edge region in which all of the conductors are fused together at their side edges to form a single consolidated conductor; and (b) a first unsolidified region in which none of the conductors are fused together; and a second fused section having: (i) a second partially solidified region wherein a majority of the mid-range of the conductor is fused together to form a second partially solidified area, the second partially solidified area providing a single consolidated conductor; and (ii) a second unsolidified region wherein none of the mid-range of the conductor is fused together.

167. A busbar for electrically connecting components in a device, the busbar comprising: a plurality of conductors arranged to provide two opposing end portions and a middle portion extending between the opposing end portions, wherein each conductor of the plurality of conductors traverses the middle portion; as well as The middle part includes: a first fused section having: (i) a first unfused section in which no conductors are fused together, and (ii) a first fused section comprising (a) a first fully solidified edge region in which all of the conductors are fused together at their side edges to form a single consolidated conductor; and (b) a first unsolidified region in which none of the conductors are fused together; and a second fused section having: (i) a second unfused section in which no conductors are fused together, and (ii) a second fused section comprising (a) a second fully solidified edge region in which all of the conductors are fused together at their side edges to form a single consolidated conductor; and (b) a second unsolidified region in which none of the conductors are fused together.

168. The busbar of any one of claims 165-167, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and The fully cured edge region extends between the uppermost conductor and the lowermost conductor and is formed using an edge welding process.

169. The busbar of any one of claims 165-167, wherein the fused section of the intermediate portion has a length, a width, and a height that together define a fused section volume; and The unsolidified area occupies most of the volume of the fusion section, while the fully solidified edge area occupies a small part of the volume of the fusion section.

170. The busbar of any one of claims 165-167, wherein the middle portion of the busbar has rigidity and the fully cured edge region occupies a first volume; and Wherein increasing the volume of the fully cured edge region increases the stiffness of the middle portion of the busbar.

171. The busbar of any one of claims 165-167, wherein the fused section is a first fused section, the fully cured edge region is a first fully cured edge region, and the uncured region is a first uncured region; and The middle portion further comprises a second fusion section, which comprises: (i) a second fully cured edge region where all conductors are fused together, and (ii) a second uncured region where none of the conductors are fused together.

172. The busbar of claim 171, wherein the first fused section is configured to have a first in-plane bend radius and the second fused section is configured to have a second in-plane bend radius, wherein the first in-plane bend radius is smaller than the second in-plane bend radius.

173. The busbar of claim 171 , wherein the first fused segment has a length, a width, and a height that together define a first fused segment volume, and the second fused segment has a length, a width, and a height that together define a second fused segment volume; and The first fully solidified edge region occupies a first percentage of the volume of the first fusion segment and the second fully solidified edge region occupies a second percentage of the volume of the second fusion segment, and the first percentage is less than the second percentage.

174. The busbar of any one of claims 165-167, wherein the fully cured edge region is formed by applying a laser to the peripheral edges of the plurality of conductors of the middle portion of the busbar.

175. The busbar of claim 174, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and The laser follows a circular pattern with an amplitude less than the height of the fused section.

176. The busbar of any one of claims 165-167, wherein the intermediate portion includes an inner weld boundary between the fully solidified edge region and the unsolidified region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary is less than 5 mm.

177. The busbar of any one of claims 165-167, wherein the intermediate portion includes an inner weld boundary between the fully solidified edge region and the unsolidified region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary varies along the length of the busbar.

178. The busbar of any one of claims 165-167, wherein the middle portion of the busbar comprises an upper edge and a lower edge; and in, The upper edge and the lower edge are rounded by applying a laser to peripheral edges of a plurality of conductors of the middle portion of the busbar.

179. The busbar of any one of claims 165-167, wherein the fully cured edge region prevents the plurality of conductors from delaminating from one another when the middle portion of the busbar is bent in a plane.

180. The busbar of any one of claims 165 and 166, wherein the second fused section is configured to have a second in-plane bend radius and the first fused section is configured to have a first in-plane bend radius, wherein the second in-plane bend radius is greater than the first in-plane bend radius.

181. The busbar of claim 180, wherein the second fused segment has a length, width, and height that together define a second fused segment volume, and the first fused segment has a length, width, and height that together define a first fused segment volume; and The second fused section occupies a second percentage of the volume of the second fused section and the fully solidified edge region occupies a first percentage of the volume of the first fused section, and the second percentage is greater than the first percentage.

182. The busbar of claim 180, wherein the second fused section has a second stiffness greater than a first stiffness of the first fused section.

183. The busbar of claim 180, wherein the second fused segment and the first fused segment are formed by applying a laser, wherein the laser follows a second pattern in the second fused segment and a first pattern in the first fused segment.

184. The busbar of claim 183, wherein the second pattern is a line waveform and the first pattern is a circular waveform.

185. The busbar of claim 184, wherein the second pattern is a triangular waveform and the first pattern is a circular waveform.

186. The busbar of claim 180, wherein the second fused section is formed using a laser and the first fully solidified edge region is formed using a cold forming process.

187. A busbar according to any one of claims 165 and 167, wherein the middle portion of the busbar further comprises a partially solidified zone, wherein a majority of the middle range of the conductor is fused together to form a partially solidified area, the partially solidified area providing a single consolidated conductor.

188. The busbar of claim 187, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack defining a fused section height, and wherein a height of the partially solidified region is less than the fused section height.

189. The busbar of claim 188, wherein the uncured region is located: (a) between the height of the fused section and the height of the partially cured region; and (b) within the partially cured zone.

190. The busbar of claim 187, wherein said intermediate portion further comprises an unfused segment, wherein none of said intermediate extents of said conductors are fused together.

191. The busbar of claim 187, wherein the length, width, and height of the fused segment of the intermediate portion collectively define a fused segment volume, and wherein the fused segment comprises a plurality of additional partially solidified regions disposed within the fused segment volume.

192. The busbar of claim 187, wherein the fused section further comprises a plurality of additional unsolidified regions, the plurality of additional unsolidified regions occupying a majority of the volume of the fused section and the partially solidified regions occupying a minority of the volume of the fused section.

193. The busbar of claim 187, wherein the intermediate portion further comprises an unfused segment having a stiffness less than a stiffness of the partially solidified region, and wherein the partially solidified region promotes in-plane bending of the fused segment of the intermediate portion.

194. The busbar of claim 187, wherein the stiffness of the partially solidified region: (a) promotes in-plane bending of the fused section of the intermediate portion; and (b) maintains the in-plane bending of the fused section over time.

195. The busbar of claim 187, wherein the partially cured region comprises an inner cured region that is denser than an outer cured region, wherein the outer cured region is located adjacent the uncured region.

196. The busbar of claim 187, wherein the partially solidified region has undergone a partial penetration welding process.

197. The busbar of claim 196, wherein a laser is used in the partial penetration welding process.

198. The busbar of claim 187, wherein the intermediate portion of the busbar has rigidity and the partially cured region occupies a first volume; and in, Increasing the volume of the partially cured region increases the stiffness of the middle portion of the busbar.

199. The busbar of any one of claims 165-167, wherein the busbar is used to interconnect battery modules in a battery pack.

200. The busbar of any one of claims 165-167, wherein at least one of the two opposing end portions comprises a fully cured region, wherein: All conductors are fused together to form a single consolidated conductor.

201. The busbar of claim 200, wherein the fully cured region is configured to engage a connector for securing the busbar to the component in the device.

202. The busbar of claim 201, wherein the connector comprises a male terminal assembly having an internal spring member.

203. A busbar according to claim 200, wherein the fully cured area is formed by applying laser to both: (a) the upper surface of the uppermost conductor of at least one end portion of the busbar; and (b) the lower surface of the lowermost conductor of at least one end portion of the busbar.

204. The busbar of claim 200, wherein the surface area of ​​the fully cured region is at least equal to 120% of the cross-sectional area of ​​the at least one end portion.

205. The busbar of claim 200, wherein the fully solidified region is formed by applying a laser, wherein the laser follows a combined pattern comprising a top fusion pattern and a bottom fusion pattern.

206. The busbar of claim 205, wherein the combination pattern is determined based on a type of connector to be coupled to the at least one end portion.

207. The busbar of claim 205, wherein the combined pattern is concentric rectangles.

208. A busbar for electrically connecting components in a device, the busbar comprising: a plurality of conductors arranged to: (i) providing two opposing end portions and a middle portion, wherein each conductor of the plurality of conductors extends between the two opposing end portions and across the middle portion, and (ii) a vertical stack having an uppermost conductor and a lowermost conductor; wherein each end portion includes a fully solidified region wherein all conductors between said uppermost conductor and said lowermost conductor are fused together to form a single consolidated conductor; and The middle portion includes an unfused section in which no conductors are fused together.

209. A busbar according to claim 208, wherein the fully cured area is formed by applying laser to both: (a) the upper surface of the uppermost conductor of the end portion of the busbar; and (b) the lower surface of the lowermost conductor of the end portion of the busbar.

210. The busbar of claim 208, wherein the fully solidified region is formed by applying a laser, wherein the laser follows a combined pattern comprising a top fusion pattern and a bottom fusion pattern.

211. The busbar of claim 210, wherein the combination pattern is determined based on a type of connector to be coupled to the end portion.

212. The busbar of claim 210, wherein the top fuse pattern is formed of concentric rectangles.

213. The busbar of claim 212, wherein the bottom fusion pattern is blank and devoid of welds.

214. The busbar of claim 212, wherein the bottom fuse pattern is formed of concentric rectangles.

215. The busbar of claim 208, wherein the surface area of ​​the fully cured region is at least equal to 120% of the cross-sectional area of ​​the at least one end portion.

216. The busbar of any one of claims 208-215, wherein the middle portion of the busbar further comprises a fused section comprising: (i) a partially cured region wherein a majority of the mid-extent of the conductor is fused together to form a partially cured area, the partially cured area providing a single consolidated conductor, and (ii) an uncured region wherein none of the mid-extent of the conductor is fused together.

217. The busbar of claim 216, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack defining a fused section height, and wherein a height of the partially solidified region is less than the fused section height.

218. The busbar of claim 217, wherein the uncured region is located: (a) between the height of the fused section and the height of the partially cured region; and (b) within the partially cured zone.

219. The busbar of claim 216, wherein the intermediate portion further comprises an unfused segment, wherein none of the intermediate extents of the conductors are fused together.

220. The busbar of claim 216, wherein the length, width, and height of the fused segment of the intermediate portion collectively define a fused segment volume, and wherein the fused segment comprises a plurality of additional partially solidified regions disposed within the fused segment volume.

221. The busbar of claim 216, wherein the fused segment further comprises a plurality of additional unsolidified regions, the plurality of additional unsolidified regions occupying a majority of the volume of the fused segment and the partially solidified regions occupying a minority of the volume of the fused segment.

222. The busbar of claim 216, wherein the intermediate portion further comprises an unfused segment having a stiffness less than a stiffness of the partially solidified region, and wherein the partially solidified region promotes in-plane bending of the fused segment of the intermediate portion.

223. The busbar of claim 216, wherein the stiffness of the partially solidified region: (a) promotes in-plane bending of the fused section of the intermediate portion; and (b) maintains the in-plane bending of the fused section over time.

224. The busbar of claim 216, wherein said fused section of said intermediate portion further comprises a fully solidified region wherein said intermediate extent of said conductor is entirely fused together to provide a single consolidated conductor.

225. The busbar of claim 224, wherein the fully solidified region has undergone a full penetration welding process.

226. The busbar of claim 225, wherein a laser is used in the full penetration welding process.

227. The busbar of claim 224, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack defining a fused segment height, and wherein a height of the fully solidified region is greater than or equal to the fused segment height.

228. A busbar according to claim 224, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fusion section height extending therebetween, and wherein the fully solidified region extends between the uppermost conductor and the lowermost conductor.

229. The busbar of claim 224, wherein the fully cured region is a fully cured edge region.

230. The busbar of claim 229, wherein the fully cured edge region prevents the plurality of conductors from delaminating from one another when the intermediate portion of the busbar is bent in-plane.

231. The busbar of claim 229, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary is less than 5 mm.

232. The busbar of claim 229, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary varies along a height of the busbar.

233. The busbar of claim 229, wherein the fully solidified edge region has undergone a full penetration welding process.

234. The busbar of claim 233, wherein the middle portion of the busbar comprises an upper edge and a lower edge; and in, The upper edge and the lower edge are rounded by applying the full penetration welding process.

235. The busbar of claim 233, wherein a laser is used in the full penetration welding process.

236. The busbar of claim 235, wherein the plurality of conductors are arranged in a vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and wherein The laser follows a circular pattern with an amplitude smaller than the height of the fused section.

237. The busbar of claim 229, wherein the fully solidified edge region has undergone a cold forming process.

238. The busbar of claim 208, wherein the fused section further comprises a fully solidified edge region.

239. The busbar of claim 238, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary is less than 5 mm.

240. The busbar of claim 238, wherein the fully cured edge region is formed by applying a laser to the edge of the middle portion of the busbar.

241. The busbar of claim 240, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and The laser follows a circular pattern with an amplitude less than the height of the fused section.

242. The busbar of claim 238, wherein the fully solidified edge region has undergone a cold forming process.

243. The busbar of claim 216, wherein the fused section is a first fused section, the partially cured region is a first partially cured region, the partially cured area is a first partially cured area, and the uncured area is a first uncured area; and The middle portion further comprises a second fusion section, which comprises: (i) a second partially cured region wherein a majority of the mid-extent of the conductor is fused together to form a second partially cured area, the second partially cured area providing a single consolidated conductor, and (ii) a second uncured area wherein none of the mid-extent of the conductor is fused together.

244. The busbar of claim 243, wherein the first fused section is configured to have a first in-plane bend radius and the second fused section is configured to have a second in-plane bend radius, wherein the first in-plane bend radius is smaller than the second in-plane bend radius.

245. The busbar of claim 243, wherein the first fused segment has a length, width, and height that together define a first fused segment volume, and the second fused segment has a length, width, and height that together define a second fused segment volume; and The first partially solidified region occupies a first percentage of the volume of the first fused section and the second partially solidified region occupies a second percentage of the volume of the second fused section, and wherein the first percentage is less than the second percentage.

246. The busbar of claim 243, wherein the first fused segment has a first stiffness that is less than a second stiffness of the second fused segment.

247. The busbar of claim 243, wherein the first partially solidified region and the second partially solidified region are formed by applying a laser, wherein the laser follows a first pattern in the first fused segment and a second pattern in the second fused segment.

248. The busbar of claim 247, wherein the first pattern is a line waveform and the second pattern is a triangle waveform.

249. The busbar of claim 247, wherein the first pattern has a first waveform frequency and the second pattern has a second waveform frequency greater than the first waveform frequency.

250. The busbar of claim 216, wherein the fused section is a first fused section, the partially cured region is a first partially cured region, the partially cured area is a first partially cured area, and the uncured area is a first uncured area; and The middle portion further comprises a second fusion section, which comprises: (i) a fully cured region wherein the mid-extents of the conductors are all fused together to form a fully cured edge region, the fully cured edge region providing a single consolidated conductor, and (ii) a second uncured region wherein none of the mid-extents of the conductors are fused together.

251. The busbar of claim 250, wherein the first fused segment is configured to have a first in-plane bend radius and the second fused segment is configured to have a second in-plane bend radius, wherein the first in-plane bend radius is greater than the second in-plane bend radius.

252. The busbar of claim 250, wherein the first fused segment has a length, a width, and a height that together define a first fused segment volume, and the second fused segment has a length, a width, and a height that together define a second fused segment volume; and wherein the first partially solidified region occupies a first percentage of the volume of the first fusion segment and the fully solidified edge region occupies a second percentage of the volume of the second fusion segment, and wherein the first percentage is greater than the second percentage.

253. The busbar of claim 250, wherein the first fused segment has a first stiffness greater than a second stiffness of the second fused segment.

254. The busbar of claim 250, wherein the first fused segment and the second fused segment are formed by applying a laser, wherein the laser follows a first pattern in the first fused segment and a second pattern in the second fused segment.

255. The busbar of claim 254, wherein the first pattern is a line waveform and the second pattern is a circular waveform.

256. The busbar of claim 255, wherein the first pattern is a triangular waveform and the second pattern is a circular waveform.

257. The busbar of claim 250, wherein the first partially cured region is formed using a laser and the fully cured edge region is formed using a cold forming process.

258. The busbar of claim 216, wherein the partially cured region comprises an inner cured region that is denser than an outer cured region, wherein the outer cured region is located adjacent the uncured region.

259. The busbar of claim 216, wherein the partially solidified region has undergone a partial penetration welding process.

260. The busbar of claim 259, wherein a laser is used in the partial penetration welding process.

261. The busbar of claim 216, wherein the middle portion of the busbar has rigidity and the partially cured region occupies a first volume; and in, Increasing the volume of the partially cured region increases the stiffness of the middle portion of the busbar.

262. The busbar of claim 216, wherein the busbar is used to interconnect battery modules in a battery pack.

263. The busbar of claim 216, wherein the busbar is used to interconnect electrical components and power sources in an electrical power distribution system.

264. The busbar of any one of claims 208-215, wherein the middle portion of the busbar further comprises a fused section, the fused section comprising: (i) fully solidified edge regions where all conductors are fused together at their side edges to form a single consolidated conductor; and (ii) uncured regions wherein none of the conductors are fused together.

265. The busbar of claim 264, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and The fully cured edge region extends between the uppermost conductor and the lowermost conductor and is formed using an edge welding process.

266. The busbar of claim 264, wherein the fused section of the intermediate portion has a length, a width, and a height that together define a fused section volume; and The unsolidified area occupies most of the volume of the fusion section, while the fully solidified edge area occupies a small part of the volume of the fusion section.

267. The busbar of claim 264, wherein the middle portion of the busbar has rigidity and the fully cured edge region occupies a first volume; and Wherein increasing the volume of the fully cured edge region increases the stiffness of the middle portion of the busbar.

268. The busbar of claim 264, wherein the fused section is a first fused section, the fully cured edge region is a first fully cured edge region, and the uncured region is a first uncured region; and The middle portion further comprises a second fusion section, which comprises: (i) a second fully cured edge region where all conductors are fused together, and (ii) a second uncured region where none of the conductors are fused together.

269. The busbar of claim 268, wherein the first fused segment is configured to have a first in-plane bend radius and the second fused segment is configured to have a second in-plane bend radius, wherein the first in-plane bend radius is smaller than the second in-plane bend radius.

270. The busbar of claim 268, wherein the first fused segment has a length, width, and height that together define a first fused segment volume, and the second fused segment has a length, width, and height that together define a second fused segment volume; and The first fully solidified edge region occupies a first percentage of the volume of the first fusion segment and the second fully solidified edge region occupies a second percentage of the volume of the second fusion segment, and the first percentage is less than the second percentage.

271. The busbar of claim 264, wherein the fully cured edge region is formed by applying a laser to the peripheral edges of the plurality of conductors in the middle portion of the busbar.

272. The busbar of claim 271 , wherein the plurality of conductors are arranged in a vertical stack, the vertical stack having an uppermost conductor and a lowermost conductor, the uppermost conductor and the lowermost conductor defining a fused section height extending therebetween, and The laser follows a circular pattern with an amplitude less than the height of the fused section.

273. The busbar of claim 264, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary is less than 5 mm.

274. The busbar of claim 264, wherein the intermediate portion includes an inner weld boundary between the fully cured edge region and the uncured region; and in, A width extending between a peripheral edge of the plurality of conductors of the intermediate portion and the inner weld boundary varies along the length of the busbar.

275. The busbar of claim 264, wherein the middle portion of the busbar comprises an upper edge and a lower edge; and in, The upper edge and the lower edge are rounded by applying a laser to peripheral edges of a plurality of conductors of the middle portion of the busbar.

276. The busbar of claim 264, wherein the fully cured edge region prevents the plurality of conductors from delaminating from one another when the middle portion of the busbar is bent in-plane.

277. The busbar of claim 264, wherein the second fused segment is configured to have a second in-plane bend radius and the first fused segment is configured to have a first in-plane bend radius, wherein the second in-plane bend radius is greater than the first in-plane bend radius.

278. The busbar of claim 277, wherein the second fused segment has a length, width, and height that together define a second fused segment volume, and the first fused segment has a length, width, and height that together define a first fused segment volume; and The second fused section occupies a second percentage of the volume of the second fused section and the fully solidified edge region occupies a first percentage of the volume of the first fused section, and the second percentage is greater than the first percentage.

279. The busbar of claim 277, wherein the second fused segment has a second stiffness greater than a first stiffness of the first fused segment.

280. The busbar of claim 277, wherein the second fused segment and the first fused segment are formed by applying a laser, wherein the laser follows a second pattern in the second fused segment and a first pattern in the first fused segment.

281. The busbar of claim 280, wherein the second pattern is a line waveform and the first pattern is a circular waveform.

282. The busbar of claim 281, wherein the second pattern is a triangular waveform and the first pattern is a circular waveform.

283. The busbar of claim 277, wherein the second fused section is formed using a laser and the first fully solidified edge region is formed using a cold forming process.

284. The busbar of claim 264, wherein the middle portion of the busbar further comprises a partially solidified zone, wherein a majority of the middle extent of the conductors are fused together to form a partially solidified region, the partially solidified region providing a single consolidated conductor.

285. The busbar of claim 284, wherein the plurality of conductors are arranged in a vertical stack, the vertical stack defining a fused section height, and wherein a height of the partially solidified region is less than the fused section height.

286. The busbar of claim 285, wherein the uncured region is located: (a) between the height of the fused section and the height of the partially cured region; and (b) in the partially cured zone.

287. The busbar of claim 284, wherein said intermediate portion further comprises an unfused segment, wherein none of said intermediate extents of said conductors are fused together.

288. The busbar of claim 284, wherein the length, width, and height of the fused segment of the intermediate portion collectively define a fused segment volume, and wherein the fused segment comprises a plurality of additional partially solidified regions disposed within the fused segment volume.

289. The busbar of claim 284, wherein the fused segment further comprises a plurality of additional unsolidified regions, the plurality of additional unsolidified regions occupying a majority of the volume of the fused segment and the partially solidified regions occupying a minority of the volume of the fused segment.

290. The busbar of claim 284, wherein the intermediate portion further comprises an unfused segment having a stiffness less than a stiffness of the partially solidified region, and wherein the partially solidified region promotes in-plane bending of the fused segment of the intermediate portion.

291. The busbar of claim 284, wherein the stiffness of the partially solidified region: (a) promotes in-plane bending of the fused section of the intermediate portion; and (b) maintains the in-plane bending of the fused section over time.

292. The busbar of claim 284, wherein the partially cured region comprises an inner cured region that is denser than an outer cured region, wherein the outer cured region is located adjacent the uncured region.

293. The busbar of claim 284, wherein the partially solidified region has undergone a partial penetration welding process.

294. The busbar of claim 293, wherein a laser is used in the partial penetration welding process.

295. The busbar of claim 284, wherein the middle portion of the busbar has rigidity and the partially cured region occupies a first volume; and in, Increasing the volume of the partially cured region increases the stiffness of the middle portion of the busbar.

Images