Battery pack with flexible bus

Abstract

The invention relates to a battery pack with flexible busbars. A flexible busbar includes a first busbar layer including a first plurality of busbar segments and a first bend between first busbar segments of the first plurality of busbar segments, and a second busbar layer coupled to the first busbar layer. The second bus bar layer includes a second plurality of bus bar segments and a second bend between second bus bar segments of the second plurality of bus bar segments. The first plurality of busbar segments are substantially collinear with the second plurality of busbar segments, and the second bend is substantially parallel to the first bend.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. non-provisional application No. 18 / 229,506, filed on August 2, 2023, entitled “BATTERY PACK WITH FLEXIBLE BUSBAR,” and U.S. non-provisional patent application No. 18 / 229,507, filed on August 2, 2023, entitled “BATTERY PACK WITH SUPPORT TABS,” the entire contents of which are hereby incorporated by reference into this document for all purposes. Background Art

[0003] As the functionality of electronic devices grows, there is a corresponding demand for battery cells used to power these electronic devices. At the same time, size and weight constraints in electronic devices limit the number and size of battery cells that can be used in electronic devices. Therefore, there is a need to maximize the energy provided by a battery pack while optimizing the shape and size of the battery pack. Summary of the invention

[0004] One aspect of the present disclosure provides a flexible busbar, the flexible busbar comprising a first busbar layer and a second busbar layer, the first busbar layer comprising a first plurality of busbar segments and a first bend, the first bend being located between first busbar segments in the first plurality of busbar segments, the second busbar layer being coupled to the first busbar layer. The second busbar layer comprises a second plurality of busbar segments and a second bend, the second bend being located between second busbar segments in the second plurality of busbar segments. The first plurality of busbar segments are substantially collinear with the second plurality of busbar segments, and the second bend is substantially parallel to the first bend. The first bend may be biased to allow the first busbar segments to be spread apart from each other, and the second bend may be biased to allow the second busbar segments to be spread apart from each other. The first bend may be biased to allow the first busbar segments to be spread apart from each other in a first direction, and the second bend may be biased to allow the second busbar segments to be spread apart from each other in the first direction. The first busbar layer may include a third bend located between a first intermediate busbar segment in the first busbar segment and a first transverse busbar segment in the first plurality of busbar segments, the second busbar layer may include a fourth bend located between a second intermediate busbar segment in the second busbar segment and a second transverse busbar segment in the second plurality of busbar segments, and the third bend may be biased to cause the first intermediate busbar segment and the first transverse busbar segment to unfold in a second direction, the second direction being different from the first direction, and the fourth bend may be biased to cause the second intermediate busbar segment and the second transverse busbar segment to unfold in the second direction. The second direction may be opposite to the first direction. The first busbar layer may include a fifth bend, the fifth bend being located between the third intermediate busbar segment in the first busbar segment and the third transverse busbar segment in the first plurality of busbar segments, the second busbar layer may include a sixth bend, the sixth bend being located between the fourth intermediate busbar segment in the second busbar segment and the fourth transverse busbar segment in the second plurality of busbar segments, the first bend may be placed between the third bend and the fifth bend along the first busbar layer, and the second bend may be placed between the fourth bend and the sixth bend along the first busbar layer. The first bend and the second bend may be offset from each other. The first bend and the second bend may overlap. The first bend and the second bend may include a first arc shape. The first busbar layer may include a third bend and the second busbar layer includes a fourth bend, the third bend and the fourth bend may include a second arc shape, and the radius of the first arc shape may be greater than the second arc shape.

[0005] Another aspect of the present disclosure provides a battery pack, the battery pack includes a first battery cell, a second battery cell and a flexible busbar, the flexible busbar electrically coupling the first battery cell and the second battery cell and being placed between the first battery cell and the second battery cell. The flexible busbar includes a busbar segment and a preformed bend, the preformed bend being located between the busbar segments. The first battery cell is placed on the second battery cell, and the busbar segments overlap each other around the preformed bend in a closed state, and the flexible busbar is configured to expand the first battery cell and the second battery cell and the busbar segment away from each other to an open state. In the open state, the first battery cell and the second battery cell can be placed transversely to each other, and the busbar segment can be expanded transversely to each other around the preformed bend. The battery pack may also include a battery management unit coupled to the first battery cell and the second battery cell. The busbar segments may be substantially parallel to each other. The first battery cell and the second battery cell may define a gap therebetween. The flexible busbar may be placed between the first battery cell and the second battery cell. The battery pack may further include a third battery cell, and the first battery cell may be placed between the third battery cell and the second battery cell.

[0006] Another aspect of the present disclosure provides a method of assembling a battery pack, the method comprising: electrically coupling a flexible busbar to a first battery cell, the flexible busbar comprising busbar segments and a preformed bend, the preformed bend being located between the busbar segments; and electrically coupling the flexible busbar to a second battery cell. The first battery cell and the second battery cell are placed transversely to each other, and the busbar segments are spread transversely to each other around the preformed bend. The method also includes: bending the flexible busbar along the flexible busbar at the preformed bend to place the first battery cell on the second battery cell. The method may also include: bending the flexible busbar at the second bend to place the first battery cell and the second battery cell closer to each other. The flexible busbar may be placed between the first battery cell and the second battery cell. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] A further understanding of the nature and advantages of the various embodiments may be achieved by reference to the following drawings. In the drawings, similar components or features may have the same reference numeral. In addition, various components of the same type may be distinguished by adding a dash and a second reference numeral after the reference numeral to distinguish between similar components. If only the first reference numeral is used in the specification, the description applies to any of the similar components having the same first reference numeral, regardless of the second reference numeral.

[0008] Figure 1AAn isometric view of a battery pack in an open state is depicted according to various embodiments of the present disclosure.

[0009] Figure 1B Depicted Figure 1A Exploded view of the battery pack.

[0010] Figure 1C Depicted Figure 1A A partial view of a battery pack.

[0011] Figure 2 Depicted are exploded views of busbars according to various embodiments of the present disclosure.

[0012] Figure 3 Depicted is a partial isometric view of a battery pack according to various embodiments of the present disclosure.

[0013] Figure 4A Depicted is an isometric view of a battery pack in a closed state according to various embodiments of the present disclosure.

[0014] Figure 4B Depicted Figure 4A A partial isometric view of a battery pack.

[0015] Figure 4C Depicted Figure 4A A partial bottom view of a battery pack.

[0016] Figure 5 Depicted is a partial isometric view of a battery pack according to various embodiments of the present disclosure.

[0017] FIG. 6A to FIG. 6C A schematic diagram of a method of installing a battery pack according to various embodiments of the present disclosure is depicted. DETAILED DESCRIPTION

[0018] Increasing the power output of a battery pack may involve certain challenges. For example, the battery cells (e.g., lithium-ion battery cells) housed in a battery pack may achieve a certain maximum voltage while minimizing the risk of overcharging the battery cells. Once that voltage level is reached, further charging of the battery cells may increase the risk of overcharging and damaging the battery cells. Therefore, one way to increase the overall power output of a battery pack includes installing more battery cells within the battery pack. However, increasing the battery cell count within a battery pack involves other challenges. For example, electrically coupling the battery cells together to charge all of the battery cells can prove challenging because the fixed characteristics of conventional busbars used to electrically couple the battery cells together can limit the battery pack to shapes and sizes that are incompatible with certain electronic devices.

[0019] The present disclosure solves this problem by providing a battery pack that is capable of accommodating multiple battery cells together to increase the total power output of the battery pack while orienting the battery cells in a space-saving manner. Specifically, multiple battery cells can be stacked together in a battery pack while still being electrically coupled using a flexible busbar, thereby increasing the total power output of the battery pack. At the same time, the flexible busbar can be bent around one or more bends along the busbar so that the battery cells can overlap each other in a manner that allows the battery pack to have a shape and size that is conducive to coupling to an electronic device. For example, the flexible busbar can enable the battery cells to be placed more compactly together to reduce the overall volume of the battery pack, thereby reducing the overall size of the battery pack. In this way, the flexible busbar can help increase the power output of the battery pack while optimizing the space occupied by the battery pack.

[0020] Several exemplary embodiments will now be described with reference to the accompanying drawings that form a part of the present disclosure. The following description only provides embodiments and is not intended to limit the scope, applicability or configuration of the present disclosure. On the contrary, the following description of the embodiments will provide an enabling description for implementing one or more embodiments to those skilled in the art. It should be understood that various changes may be made to the functions and arrangements of the elements without departing from the spirit and scope of the present disclosure. In the following description, specific details are set forth for the purpose of explanation in order to provide a thorough understanding of certain embodiments of the present invention. However, it will be apparent that various embodiments may be practiced without these specific details. The drawings and description are not intended to be limiting.

[0021] Although the remainder of the specification will often refer to lithium-ion battery cells, those skilled in the art will readily appreciate that the technology of the present disclosure is not limited thereto. The designs of the present disclosure can be used with any number of batteries or energy storage devices, including other rechargeable and primary or non-rechargeable battery types as well as electrochemical capacitors (also known as supercapacitors or ultracapacitors), electrolyzers, fuel cells, and other electrochemical devices. In addition, the technology of the present disclosure can be applied to battery cells and energy storage devices that can be used in any number of technologies, which can include but are not limited to phones and mobile devices, handheld electronic devices, wearable devices, laptops and other computers, appliances, heavy machinery, transportation equipment, spacecraft electronic payloads, vehicles, and any other device that can use battery cells or benefit from the designs discussed. Therefore, the present disclosure and claims should not be considered limited to any specific discussed examples, but can be widely used with any number of devices, which may exhibit some or all of the electrical or chemical characteristics of the discussed examples.

[0022] I. Exemplary Battery Packs

[0023] Figures 1A to 1CAn example battery pack 100 according to various embodiments of the present disclosure is depicted. The battery pack 100 includes battery cells 101a-101c, a board 110, a battery management unit (BMU) 120, and a flexible busbar 130. The battery cells 101a-101c may be or include battery cells, and may be one of a plurality of cells coupled together to form a battery structure. The BMU 120 may be configured to control the operation of the battery cells 101a-101c. The BMU 120 may also be operable to electrically couple the battery cells 101a-101c to components that utilize power from the battery cells 101a-101c, and to electrically couple to components that provide power to charge the battery cells 101a-101c. The battery cells 101a, 101b, and the BMU 120 may be electrically coupled to each other via the flexible busbar 130. The battery cell 101c may be electrically coupled to the BMU 120 separately from the other battery cells 101a, 101b. For example, battery cell 101c may be electrically coupled directly to BMU 120 without an intermediate busbar. However, in other embodiments, the bottom battery cell may be electrically coupled to the BMU via a busbar separate from the flexible busbar. In yet other embodiments, the flexible busbar may additionally couple the bottom battery cell to the BMU. Plate 110 may be placed between battery cells 101b, 101c and coupled to the battery cell. BMU 120 may be coupled to plate 110 at one end adjacent to plate 110. Plate 110 may be made of a metal such as stainless steel or any other suitable rigid material. It should be understood that the battery pack 100 may include additional components not provided in the present disclosure, such as pads and / or tabs for attaching the battery pack 100 to other components.

[0024] As described above, increasing the number of battery cells within a battery pack can increase the power output of the battery pack. However, it can be difficult to electrically couple these battery cells together without limiting the shape and size of the battery pack to a particular configuration that is less capable of coupling to an electronic device. Specifically, non-flexible busbars (e.g., rigid busbars that cannot withstand significant bending without being damaged) are unable to couple multiple battery cells together and cannot be manipulated to allow the battery cells to be reoriented in a manner that provides a space-saving battery pack.

[0025] The flexible busbar 130 can solve this problem by electrically coupling the battery cells 101a-101c together while being flexible enough to orient the battery cells 101a-101c together in a manner that allows the battery pack 100 to have a shape and size that can be optimally and efficiently coupled to other electronic devices. Specifically, the flexible busbar 130 can flexibly place one or more of the battery cells 101a-101c from an open (or first) state (e.g., when the battery cells 101a-101c are initially electrically coupled together with the flexible busbar 130) to a closed (or second) state (e.g., when the battery pack 100 is ready to be coupled to an electronic device). The battery pack 100 can be formed in an open state at a first facility (e.g., where the battery cells 101a-101c are electrically coupled to the busbar 130) and transported to a second facility where the battery pack 100 is transformed to a closed state (e.g., where the battery pack 100 is coupled to an electronic device). The battery pack 100 may be transported in the first state because the battery pack 100 may be more securely positioned in the transport pallet in the open state. Specifically, the battery cells 101a-101c may be secured to the transport pallet (e.g., by padding) to minimize relative movement of the components of the battery pack 100 with respect to each other during transport. In contrast, it may be more difficult to secure the battery cells 101a-101c to the transport pallet in the closed state, resulting in a greater likelihood that the components of the battery pack 100 may move relative to each other and the battery pack 100 may be damaged. However, in other embodiments, the battery pack 100 may be formed in the first state and transitioned to the closed state while being transported entirely in the first facility.

[0026] Figure 1A The battery pack 100 is depicted in an open (or first) state. In the open state, the battery cells 101a, 101b are placed transversely to each other along the X-axis. In addition, certain portions of the flexible busbars 130 are spread transversely to each other along the X-axis, as will be discussed further below. In this way, the flexible busbars 130 can facilitate electrical connections between the battery cells 101a-101c and the BMU 120.

[0027] Go to Figure 1C, the flexible busbar 130 may include busbar layers 132a, 132b. The busbar layers 132a, 132b may be formed of metal (e.g., copper, aluminum, stainless steel, brass, or other suitable materials), non-metallic materials (such as polymers (e.g., polyimide or other suitable non-metallic materials)), or composite materials that may include conductive materials. The width of the busbar layers 132a, 132 along the Y direction may be between about 1 mm and 5 mm, such as between about 2 mm and 4 mm, between about 2.5 mm and 3.5 mm, or about 3 mm, respectively. The width of the busbar layers 132a, 132 along the Z direction may be between about 0.05 mm and 0.5 mm, such as between about 0.1 mm and 0.4 mm, between about 0.15 mm and 0.3 mm, or about 0.2 mm, respectively. For example, each of the busbar layers 132a, 132b may include a copper layer between polyimide layers. In this example, the thickness of the copper layer along the Z direction may be between about 50 μm and 150 μm, such as between about 70 μm and 130 μm, between about 90 μm and 110 μm, or about 100 μm. The thickness of the polyimide layer along the Z direction may be between about 25 μm and 75 μm, such as between about 35 μm and 65 μm, between about 45 μm and 65 μm, or about 50 μm. However, in other embodiments, the busbar layer may be formed of a single material or a combination of other materials. The busbar layers 132a, 132b may be coupled together by bonding (e.g., a pressure-sensitive adhesive) or by other coupling devices. Therefore, the busbar layers 132a, 132b may move in unison with each other.

[0028] Each of the busbar layers 132a, 132b may electrically couple certain terminals (not shown) of the battery cells 101a, 101b and the BMU 120 to each other. For example, the busbar layers 132a, 132b may enable the battery cells 101a, 101b and the BMU 120 to be connected in parallel or in series with each other. In one example, the busbar layers 132a, 132b may electrically couple the terminals (e.g., positive terminals or negative terminals) of the battery cells 101a, 101b to the BMU 120, as well as to each other (e.g., the positive terminal of the battery cell 101a is electrically coupled to the negative terminal of the battery cell 101b). Although only two busbar layers 132a, 132b are shown, in other embodiments, there may be more than two busbar layers (e.g., where more battery cells and / or terminals are coupled together).

[0029] Each of the busbar layers 132a, 132b may include intermediate busbar sections 136a, 136b, 137a, 137b and transverse busbar sections 138a, 138b, 139a, 139b, respectively. The intermediate busbar sections 136a, 137a may define an intermediate bend 131a therebetween along the layer 132a. The intermediate busbar sections 136b, 137b may define an intermediate bend 131b therebetween along the layer 132b. The intermediate busbar sections 136a and the transverse busbar sections 138a may define a transverse bend 134a therebetween along the layer 132a. The intermediate busbar sections 136b and the transverse busbar sections 138b may define a transverse bend 134b therebetween along the layer 132b. The intermediate busbar sections 137a and the transverse busbar sections 139a may define a transverse bend 135a therebetween along the layer 132a. The intermediate bus-segments 137b and the transverse bus-segments 139b may define a transverse bend 135b therebetween along the layer 132b.

[0030] The flexible busbar 130 can be flexible because it can be bent along the Y axis around the intermediate bends 131a, 131b and the transverse bends 134a, 134b, 135a, 135b. Specifically, each of the intermediate busbar sections 136a, 136b, 137a, 137b can rotate relative to each other around the corresponding intermediate bends 131a, 131b. The intermediate busbar sections 136a, 136b can rotate relative to the transverse busbar sections 138a, 138b around the corresponding transverse bends 134a, 134b. The intermediate busbar sections 137a, 137b can rotate relative to the transverse busbar sections 139a, 139b around the corresponding transverse bends 135a, 135b. The busbar sections 136a, 136b, 137a, 137b, 138a, 138b, 139a, 139b may be rigid to bend around the bends 131a, 131b, 134a, 134b, 135a, 135b without significant deformation (e.g., less than 10°, such as less than 5° or no deformation) of the busbar sections 136a, 136b, 137a, 137b, 138a, 138b, 139a. Therefore, the busbar sections 136a, 136b, 137a, 137b, 138a, 138b, 139a, 139b may be less flexible than the bends 131a, 131b, 134a, 134b, 135a, 135b.

[0031] The bends 131a, 131b, 134a, 134b, 135a, 135b may be preformed along the flexible busbar 130 (e.g., by bending the flexible busbar 130 around one or more pins during manufacturing) to bias toward a rest position. In the rest position, the bends 131a, 131b, 134a, 134b, 135a, 135b may include a shape to which the bends 131a, 131b, 134a, 134b, 135a, 135b will return in the absence of an external force. Thus, the bends 131a, 131b, 134a, 134b, 135a, 135b may bias the busbar segments 136a, 136b, 137a, 137b, 138a, 138b, 139a, 139b to the rest position. For example, the bent portions 131a, 131b, 134a, 134b, 135a, 135b may be pre-formed to have a shape such as Figure 1C Thus, the intermediate bends 131a, 131b may offset the busbar segments 136a, 136b, 137a, 137b about the Y axis in an angular direction opposite to the angular direction of the lateral bends 134a, 134b, 135a, 135b. However, in other embodiments, the intermediate bends may offset the flexible busbars in substantially similar angular directions as the lateral bends (e.g., each of these bends may be offset in angular directions within about 20% of each other, such as about 10%, such as about 5%, or identical).

[0032] In addition, the bends 131a, 131b, 134a, 134b, 135a, 135b can be pre-formed to allow for a greater degree of rotation about the Y axis. However, as discussed further below, the bends 131a, 131b, 134a, 134b, 135a, 135b can allow for rotation about any axis. However, in other embodiments, the bends can be pre-formed to have any static position, such that the busbar segments have a static position. In the static position, the busbar segments are at any angle relative to each other.

[0033] The bends 131a, 131b, 134a, 134b, 135a, 135b may be preformed to have an arc shape to minimize the risk of creases when the flexible busbar 130 is bent at these locations. In the absence of an arc shape, such creases may increase the risk of cracks forming at the bend and damaging the flexible busbar. The arc radius of the intermediate bends 131a, 131b may be greater than the arc radius of the lateral bends 134a, 134b, 135a, 135b because the intermediate bends 131a, 131b may be subjected to more flexion, as further described below. However, in other embodiments, the bends do not have an arc shape, but may define a sharp bend. In some other embodiments, the arc radii of all of the bends in these bends may be substantially similar (e.g., the radii of the bends may deviate from each other by about 20%, such as by about 10%, such as by about 5% or are exactly the same). In another embodiment, the arc radius of the lateral bend may be greater than the arc radius of the intermediate bend.

[0034] The bends 131a, 131b, 134a, 134b, 135a, 135b may be sufficiently flexible so that the maximum rotation angle around the bends 131a, 131b, 134a, 134b, 135a, 135b from the open state to the closed state is limited by the size of the bus sections 136a, 136b, 137a, 137b, 138a, 138b, 139a, 139b. For example, the intermediate bus sections 136a, 136b, 137a, 137b may be bent around the intermediate bends 131a, 131b from an open state in which the intermediate bus sections 136a, 136b, 137a, 137b are unfolded to a closed state in which at least a portion of the intermediate bus sections 136a, 137a are in contact with each other. Similarly, the intermediate bus-bar sections 136a, 136b and the transverse bus-bar sections 138a, 138b can be bent around the transverse bends 134a, 134b from an open state in which the bus-bar sections 136a, 136b, 138a, 138b are deployed to a closed state in which at least a portion of the intermediate bus-bar section 136b and the transverse bus-bar section 138b are in contact with each other. The intermediate bus-bar sections 137a, 137b and the transverse bus-bar sections 139a, 139b can be bent around the transverse bends 135a, 135b from an open state in which the bus-bar sections 137a, 137b, 139a, 139b are deployed to a closed state in which at least a portion of the intermediate bus-bar section 136b and the transverse bus-bar section 138b are in contact with each other. As will be discussed further below, when the flexible busbar 130 is in a closed state, the busbar segments 136a, 136b, 137a, 137b, 138a, 138b, 139a, 139b may overlap each other along the Z-axis and may be at least substantially parallel to each other without at least partially contacting each other. Substantially parallel means that the busbar segments 136a, 136b, 137a, 137b, 138a, 138b, 139a, 139b may have an angle of less than or about 30°, such as less than or about 20°, such as less than or about 10°, or may be completely parallel to each other.

[0035] The bends 131a, 131b, 134a, 134b, 135a, 135b may be sufficiently flexible so that the flexible busbar 130 may be transformed from a maximum open state (i.e., an open state in which the bends 131a, 131b, 134a, 134b, 135a, 135b do not crack after 30 cycles of rotation from the open state to the closed state) to a closed state. For example, the intermediate busbar segments 136a, 136b, 137a, 137b may be rotated relative to each other around the intermediate bends 131a, 131b from a maximum open state to a closed state, wherein the busbar segments 136a, 136b, 137a, 137b are at a transverse angle to each other around the Y axis, and portions of the busbar segments 136a, 136b, 137a, 137b that are away from the intermediate bends 131a, 131b are higher along the Z axis than the bends 131a, 131b. Thus, the available rotation angle of the intermediate curved portions 131a, 131b from the open state to the closed state can be between about 0° to about 360°, such as between about 50° to about 330°, between about 100° to about 300°, between about 150° to about 270°, or about 240°. The intermediate busbar segments 136a, 136b, 137a, 137b and the transverse busbar segments 138a, 138b, 139a, 139b can be rotated relative to each other around the corresponding transverse curved portions 134a, 134b, 135a, 135b from an open state in which the busbar segments 136a, 136b, 137a, 137b, 138a, 138b, 139a, 139b are substantially parallel to each other to a closed state. Therefore, the available rotation angle of the lateral bends 134a, 134b, 135a, 135b may be between about 0° and about 180°, such as between about 30° and about 150°, between about 60° and about 120°, or about 90°. The available rotation angle of the intermediate bends 131a, 131b may be greater than the available rotation angle of the lateral bends 134a, 134b, 135a, 135b to allow the intermediate bends 131a, 131b to bend more with less risk of damage. Since the intermediate bends 131a, 131b may need to bend more than the lateral bends 134a, 134b, 135a, 135b when installing the battery pack 100 (e.g., when the battery pack 100 is transitioned from an open state to a closed state, as will be discussed further below), the larger available rotation angle allows the intermediate bends 131a, 131b to bend as needed while minimizing the risk of damage to the intermediate bends 131a, 131b. However, in other embodiments, the lateral bends may have a substantially similar rotation angle to the intermediate bends (e.g., the rotation angles of each bend may deviate from each other by within about 20%, such as by about 10%, such as by about 5%, or are exactly the same).

[0036] The busbar layers 132a, 132b may be substantially collinear with each other. In other words, most of the busbar layers 132a, 132b may at least partially overlap along the XY plane and be substantially parallel to each other along the same axis (e.g., the X axis). For example, the busbar segments 136a, 136b, 137a, 137b, 138a, 138b, 139a, 139b may be substantially collinear with each other. In addition, the widths of these busbar segments 136a, 136b, 137a, 137b, 138a, 138b, 139a, 139b may be substantially similar to minimize the impedance across the busbar layers 132a, 132b (e.g., the widths of each of the busbar segments 136a, 136b, 137a, 137b, 138a, 138b, 139a, 139b may be within about 20% of each other, such as about 10%, such as about 5% or exactly the same). However, since certain portions of the busbar layers 132a, 132b move relative to each other when the flexible busbar 130 transitions from an open state to a closed state, certain portions of the flexible busbar 130 have smaller cross-sectional widths and are offset from each other. Specifically, the bends 131a, 131b, 134a, 134b, 135a, 135b may be offset from one another (e.g., no portions of the bends 131a, 131b, 134a, 134b, 135a, 135b overlap one another, as discussed below). Although the bends 131a, 131b, 134a, 134b, 135a, 135b are substantially parallel to one another so that the busbar layers 132a, 132b may be concentrically bent around the same axis, the intermediate bends 131a, 131b, the lateral bends 134a, 134b, and the lateral bends 135a, 135b may be offset from one another, respectively. Such offsets allow the flexible busbar 130 to be flexible while minimizing the risk that the busbar layers 132a, 132b may separate from one another.

[0037] The busbar layers 132a, 132b may define intermediate cutouts 140a, 140b, and the busbar layers 132a, 132b may define transverse cutouts 141a, 141b, 142a, 142b. Specifically, the intermediate bends 131a, 131b and the intermediate busbar sections 136a, 136b, 137a, 137b may define intermediate cutouts 140a, 140b therebetween. The transverse bends 134a, 134b, the intermediate busbar sections 136a, 136b, and the transverse busbar sections 138a, 138b may define transverse cutouts 141a, 141b therebetween. The transverse bends 135a, 135b, the intermediate busbar sections 137a, 137b, and the transverse busbar sections 139a, 139b may define transverse cutouts 142a, 142b therebetween. The cutouts 140a, 140b, 141a, 141b, 142a, 142b may include a generally rectangular shape. However, in other embodiments, the cutouts may include any other shape, such as a circle, a triangle, etc. The intermediate cutouts 140a, 140b, the transverse cutouts 141a, 141b, and the transverse cutouts 142a, 142b may be offset from one another. In this way, the bends 131a, 131b, 134a, 134b, 135a, 135b may be offset from one another so that when viewed in the Z direction, the bends 131a, 131b, 134a, 134b, 135a, 135b may be exposed through the cutouts 140a, 140b, 141a, 141b, 142a, 142b.

[0038] For example, if the bends of the busbar layers have similar radii (e.g., have a radius difference of less than about 10%, such as a radius difference of less than about 5%, or no radius difference), but are not offset but placed on top of each other, bending the busbar layers may result in displacement between adjacent busbar segments. Such displacement may increase the risk of the busbar layers becoming separated from each other. Since the radii of the bends 131a, 134a, 135a and the bends 131b, 134b, 135b are substantially similar, offsetting the bends 131a, 134a, 135a and the bends 131b, 134b, 135b from each other by corresponding cutouts 140a, 140b, 141a, 141b, 142a, 142b may solve this problem. Specifically, during the movement of the flexible busbar 130 around the bends 131a, 131b, 134a, 134b, 135a, 135b, none of the busbar layers 132a, 132b need to bend around the other. Therefore, the busbar segments 136a, 137a, 138a, 139a of the busbar layer 132a are not displaced relative to the busbar segments 136b, 137b, 138b, 139b of the busbar layer 132b. Therefore, the bends 131a, 134a, 135a and the bends 131b, 134b, 135b are offset from each other, so that the flexible busbar 130 is flexible around the bends 131a, 131b, 134a, 134b, 135a, 135b, while reducing the risk of the busbar layers 132a, 132b separating from each other.

[0039] Although in Figures 1A to 1C Three battery cells 101a-101c are depicted in FIG, but in other embodiments, there may be two battery cells or more than three battery cells. For example, the battery pack may include only two battery cells electrically coupled to each other via a flexible busbar. In other examples, there may be more than three battery cells coupled to each other by extending the length of the flexible busbar and increasing the number of features for coupling the battery cells together (e.g., increasing the number of tabs for coupling the battery cells, as discussed further below). The peak power output of the battery pack 100 may be based on the number of battery cells. For example, in the case of three battery cells, the peak power output of the battery pack may be between about 20 watts and 150 watts, such as between about 30 watts and 140 watts, between about 40 watts and 120 watts, between about 50 watts and 100 watts, between about 60 watts and 80 watts. Such peak power output may change corresponding to the number of battery cells electrically coupled together in the battery pack. Such peak power output may allow the battery pack 100 to be used with a variety of electronic devices. For example, the battery pack 100 may be electrically coupled to an electronic device that requires peak power output as described above (eg, up to 150 watts for three battery cells).

[0040] The busbar layers 132a, 132b can be flat along the XY plane (e.g., having a rectangular cross-sectional shape). However, in other embodiments, the flexible busbars can have other shapes, such as having a cylindrical shape (e.g., as a wire or cable). The flat shape can have a higher rigidity (e.g., along the busbar segments 136a, 136b, 137a, 137b, 138a, 138b, 139a, 139b) relative to other shapes, so that the busbar layers 132a, 132b can better maintain their shape during and after assembly. For example, the flat busbar layers 132a, 132b may not sag as much in a closed state (e.g., as compared to other shapes (such as if the busbar layers included a cylindrical shape). FIG. 4A to FIG. 4C ). However, in other shapes (e.g., a cylindrical shape), the busbar layer may be more flexible, allowing greater freedom of movement in positioning the battery cells relative to each other.

[0041] Figure 2 An example flexible busbar 230 is depicted. It should be understood that features ending with the same reference numerals as the above-described features are similar except as noted below. Busbar layer 232b includes tabs 241b extending from transverse busbar segment 239b and tabs 242b, 243b extending from transverse busbar segment 238b. Busbar layer 232a includes tabs 241a extending from transverse busbar segment 239a and tabs 242a extending from transverse busbar segment 238a.

[0042] Tabs 241a, 242a, 241b, 242b, 243b may each be configured to electrically couple to other components in the battery pack (e.g., battery cells and BMUs, such as one of battery cells 101a-101c and BMU 120). For example, tab 241b may be electrically coupled to the positive terminal of a first battery (e.g., battery cell 101b), tab 243b may be electrically coupled to the negative terminal of a second battery (e.g., battery cell 101a), and tab 242b may be electrically coupled to a BMU (e.g., BMU 120). In this way, busbar layer 232b may electrically couple the first battery and the second battery to the BMU. In addition, tab 241a may be electrically coupled to the negative terminal of the first battery, and tab 242a may be electrically coupled to the BMU. In this way, busbar layer 232b may electrically couple the first battery to the BMU. However, the tabs may be electrically coupled to any other combination of positive and negative terminals.

[0043] The position, shape and size of the tabs 241a, 242a, 241b, 242b, 243b relative to the transverse busbar segments 238a, 238b, 239a, 239b can be adjusted according to the position of those other components. For example, although the tabs 241a, 242a, 241b, 242b, 243b are depicted as being substantially parallel along the XY plane, but offset from the transverse busbar segments 238a, 238b, 239a, 239b, in other embodiments, the tabs may be coplanar with the transverse busbar segments. In addition, the tab 241a may be bent to be placed below the transverse busbar segment 239a along the Z axis, and the tab 243b may be bent to be placed below the transverse busbar segment 238b along the Z axis. In other embodiments, the tabs may be bent to be located above the busbar segments, or may not be bent to be located below or above the busbar segments. Additionally, tabs 242a, 242b, 243b extend from transverse bus-segments 238a, 238b along the Y axis, while tab 241b extends from transverse bus-segment 239b along the X axis. However, the tabs may extend from the transverse bus-segments along either of these axes.

[0044] In addition, the shape and size of the transverse bus segments 238a, 238b, 239a, 239b can be adjusted to take into account other components of the battery pack. For example, portions of the transverse bus segments 238a, 238b may be offset (e.g., along the Y axis) from the transverse bus segments 239a, 239b to take into account the positions of other components of the battery pack (such as the BMU) or the terminals of the battery cells. In other embodiments, the bus segments may have any other shape, including symmetry about a bend, etc. In addition, the transverse bus segments 238b, 239a may be longer than the transverse bus segments 238a, 239b. However, in other embodiments, the lengths of the transverse bus segments may be reversed or substantially similar (e.g., the lengths of each of the bus segments may deviate from each other by within about 20%, such as by about 10%, such as by about 5% or exactly the same).

[0045] Figure 3An example battery pack 300 according to various embodiments of the present disclosure is depicted. It should be understood that features ending with the same reference numerals as the above-described features are similar, except as noted below. The flexible busbar 330 may include busbar layers 332a, 332b defining bends 331a, 331b, 334a, 334b, 335a, 335b. The bends 331a, 334a, 335a of the busbar layer 332a may overlap and be parallel to the bends 331b, 334b, 335b of the busbar layer 332b, rather than being offset. The bends 331a, 331b, 334a, 334b, 335a, 335b may overlap each other so that no portion of the bends 331a, 334a, 335a extends beyond 331b, 334b, 335b in the Y direction. However, in other embodiments, a portion of at least one of the bends may extend beyond the corresponding overlapping bends. In addition, the cutouts 340a, 340b, 341a, 341b, 342a, 342b may not be offset from each other. However, in other embodiments, there may be no cutouts, so that the width of the bends and busbar segments along the length of the busbar layer is substantially the same. This embodiment may be beneficial because the busbar layers 332a, 332b stacked on each other along the bends 331a, 331b, 334a, 334b, 335a, 335b will increase the rigidity and structural integrity of the bends 331a, 331b, 334a, 334b, 335a, 335b. Although the busbar layers 332a, 332b define bends 331a, 331b, 334a, 334b, 335a, 335b with a width that is less than the width of other portions of the busbar layers 332a, 332b (ie, along the busbar segments), in other embodiments the busbar layers may have a similar width along their length.

[0046] FIG. 4A to FIG. 4C An example battery pack 400 according to various embodiments of the present disclosure is depicted. It should be understood that, except as noted below, features ending with the same reference numerals as the above-described features are similar. Battery pack 400 may be the same as battery pack 100 except that battery pack 400 is in a closed state. In this closed state, battery cells 101a-101c are all at least partially placed along the Z axis and overlap each other. This stacked position may be beneficial in minimizing the total area occupied by battery pack 400 along the XY plane, which may allow battery pack 400 to be more easily installed in an electronic device. However, in other embodiments, the battery cells may not be stacked along the Z axis, but may be placed relative to each other in any manner required for installation in an electronic device.

[0047] The board 410 may include a board body 411 having an extension 412 extending from the board body 411. The battery cells 401a, 401c may be coupled to opposite sides of the board body 411 (e.g., using an adhesive, etc.). The extension 412 may define a slot 413. The extension 412 and the slot 413 may be configured to engage with other components, such as a housing (not shown) of an electronic device. In this way, the board body 411 and other components coupled to the board body 411 (e.g., battery cells 401a, 401c) may be suspended within the electronic device. In other embodiments, there may be any number of extensions extending from the board body, each of which may extend in any direction and may have any shape or size. In addition, in other embodiments, there may be any number of slots defined by the extensions, each of which may have any size or shape.

[0048] The battery cells 401a-401c may be offset from each other along the X-axis and the Y-axis to account for other components, or to account for the specific geometry of the electronic device in which the battery pack 400 will be installed. For example, the battery cell 401a may be offset from the battery cells 401b, 401c along the Y-axis to account for the space occupied by the BMU 420. In this way, the BMU 420 may extend beyond the board 410 along the Y-axis so that the ends of the BMU 420 and the battery cells 401b, 401c are coplanar with each other. However, in other embodiments, the battery cells may all be substantially colinear with each other when stacked along the Z-axis.

[0049] Go to Figure 4B and Figure 4C , the busbar segments 436a, 436b, 437a, 437b, 438a, 438b, 439a, 439b are bent around the bends 434a, 434b, 434a, 434b, 435a, 435b so that the busbar segments 436a, 436b, 437a, 437b, 438a, 438b, 439a, 439b overlap along the Z axis. The busbar segments 436a, 436b, 437a, 437b, 438a, 438b, 439a, 439b may be substantially parallel to each other.

[0050] The construction of the battery pack 400 may additionally consider the expansion of the battery cells 401a-401c. Specifically, when installed in an electronic device, the battery pack 400 may be coupled to the electronic device by fixing the plate 410 to the electronic device. In this configuration, the plate 410 may be suspended in the air because the plate 410 may be fixed to the electronic device along the Z axis at a distance from other components of the electronic device. When the battery cells 401a, 401c are coupled to the plate 410, the battery cells 401a, 401c may be suspended in the air accordingly. At the same time, the battery cell 401b may be placed below the battery cells 401a, 401c. The battery cell 401b may be coupled to a portion of the electronic device below the battery cells 401a, 401c. In this configuration, the gap h may be defined between the battery cell 401a suspended in the air by the plate 410 and the battery cell 401b placed below the battery cell 401a.

[0051] The gap h may take into account the expansion of the battery cells 401a, 401b (for example, when the battery cells 401a, 401b become hot). Figure 4C The gap h depicted in is for illustrative purposes only, and the battery cells 401a, 401b may be farther or closer than shown to define the gap h. In use, when the battery cells 401a, 401b expand, the gap h provides space for the battery cells 401a, 401b to expand toward each other. When the battery cells 401a-401c expand, this can help reduce the stress applied to the electronic device. For example, if the battery cells are coupled to the electronic device without gaps, the expansion of the battery cells will apply stress to other battery cells and the electronic device, which may cause damage to the battery cells or the electronic device. The gap h solves this problem by providing some space for this expansion, so that when the battery pack 400 is in use, less stress can be applied to the battery cells 401a, 401b and the electronic device.

[0052] When the battery cells 401a, 401b are not expanding (e.g., at a static temperature when not in use, such as Figure 4C ), the gap h may have a maximum size. The gap h may increase and decrease as the battery cells 401a, 401b heat up and expand, then cool and return to their resting size. In addition, as the battery cells 401a, 401b expand into the gap h and then decrease in size, one or more of the bends 434a, 434b, 434a, 434b, 435a, 435b may also be compressed and expanded accordingly along the Z axis as the transverse busbar segments 436a, 436b, 437a, 437b move toward and away from each other.

[0053] Figure 5A partial view of an exemplary battery pack 500 according to various embodiments of the present disclosure is depicted. It should be understood that features ending with the same reference numerals as the above-described features are similar, except as noted below. The busbar layers 532a, 532b may define bends 544a, 544b between transverse busbar segments 539a, 539b and end busbar segments 545a, 545b, respectively. One of the transverse busbar segments 539a, 539b or the end busbar segments 545a, 545b may be coupled to the battery cell 501b (e.g., by an adhesive, etc.), while the other set of busbar segments 539a, 539b, 545a, 545b is not coupled to the battery cell 501b. For example, the end busbar segments 545a, 545b may be coupled to the battery cell 501b, while the transverse busbar segments 539a, 539b are not coupled to the battery cell 501b. In this way, when in use and the battery pack 500 is in a closed state, the end busbar sections 545a, 545b can adapt to the expansion of the battery cell 501b. Specifically, when the battery cell 501b expands, the end busbar sections 545a, 545b can move with the expansion by rotating around the bends 544a, 544b.

[0054] In some embodiments, the curved portions 544a, 544b may be preformed to have a Figure 5 530. The resting shape shown. Thus, when the battery cell 501b cools, the bends 544a, 544b and busbar segments 539a, 539b will be biased to return to the resting shape. In some embodiments, the other end of the busbar 530 may also include a similar configuration of busbar segments 539a, 539b, 545a, 545 and bends 544a, 544b to account for expansion of the battery cell 501a. In another embodiment, the lateral busbar segments may be coupled to the battery, while the end busbar segments are not coupled to the battery. In yet another embodiment, neither the lateral busbar segments nor the end busbar segments are coupled to the battery, while the bends are coupled to the battery.

[0055] II. Exemplary Method of Installing a Battery Pack

[0056] FIG. 6A to FIG. 6C A simplified view of an example method of installing a battery pack 600 from an open state to a closed state according to various embodiments of the present disclosure is depicted. It should be understood that features ending with the same reference numerals as the above-described features are similar, except as noted below. As an initial step, the battery cells 601a, 601c may be coupled together (e.g., by adhering to opposite sides of a board (such as board 110), as previously discussed). The flexible busbar 630 may then electrically couple the battery cells 601a, 601b and the BMU (not shown) together adjacent to the bends 634, 635.

[0057] Go to Fig. 6A, the flexible busbar 630 and the battery cells 601a, 601c can be rotated about the Y axis about the bend 635, as shown by arrow A. The flexible busbar 630 and the battery cells 601a, 601c can be rotated until the middle bend 631 points in the X direction. For example, the flexible busbar 630 and the battery cells 601a, 601c can be rotated substantially by about 90°, such as between about 30° to about 120°, between about 50° to about 110°, or between about 70° to about 100°.

[0058] Go to Figure 6B , the battery cells 601a, 601c can be rotated about the Y axis about the bend 634, as shown by arrow B. The battery cells 601a, 601c can be rotated about the Y axis about the bend 634 until the battery cells 601a, 601c are placed above the battery cell 601b along the Z axis. For example, the battery cells 601a, 601 can be rotated substantially by about 90°. It should be understood that any of the rotations about arrows A, B can be performed in any order. For example, before rotating the flexible busbar 630 and the battery pack cells 601a, 601c about arrow A, the battery cells 601a, 601c can be rotated about arrow B. The battery cell 601b can be coupled to the electronic device at this point (e.g., by an adhesive), however, in other embodiments, the battery can be coupled to the electronic device at any point in the process.

[0059] Go to Figure 6C , the battery cells 601a, 601c can be moved along the Z axis toward the battery cell 601b until the battery pack 600 is in a closed state. For example, the battery cells 601a, 601c can be moved toward the battery cell 601b until the busbar segments 636, 637 are substantially parallel to each other (e.g., as shown in FIG. FIG. 4A to FIG. 4C Although not shown, the cells 601a, 601c may include additional movement to move the cells 601a, 601c to a closed state relative to the cell 601b. For example, the cells 601a, 601c may translate along any of the X-axis, Y-axis, or Z-axis, and may include additional rotation about any of the X-axis, Y-axis, or Z-axis about the bends 634, 635. In other embodiments, any of the cells may rotate or translate about the busbar relative to each other, rather than just one group of cells rotating or translating toward another, such as FIG. 6A to FIG. 6C The battery cells 601a, 601c may be coupled to an electronic device (eg, via a board, such as board 110, as discussed above).

[0060] In the foregoing description, embodiments of the present disclosure have been described with reference to many specific details that can vary from one specific implementation to another. Accordingly, the description and drawings should be regarded as having illustrative rather than restrictive meanings. The scope of the present disclosure and the only and exclusive indication of what is intended by the applicant to be the scope of the present disclosure is the literal and equivalent scope of a set of claims issued from this patent application in the specific form issued with such claims, including any subsequent corrections. The specific details of a particular embodiment can be combined in any suitable manner without departing from the spirit and scope of the embodiments of the present disclosure.

[0061] In addition, spatially relative terms, such as "bottom" or "top", etc. can be used to describe the relationship of one element and / or feature to another or more elements and / or another or more features, as illustrated in the figures, for example. It should be understood that spatially relative terms are intended to cover different orientations of the device in use and / or operation in addition to the orientation depicted in the figures. For example, if the device in the figure is turned over, the element described as the "bottom" surface can then be oriented to be "above" other elements or features. The device can be oriented in other ways (e.g., rotated 90 degrees or at other orientations), and the spatially relative descriptors used in this article are interpreted accordingly.

[0062] As used herein, the terms "and", "or" and "and / or" may include multiple meanings, which are also expected to depend at least in part on the context in which such terms are used. Generally, if used in an associative list (such as A, B, or C), "or" is intended to mean A, B, and C (used here in an inclusive sense) as well as A, B, or C (used here in an exclusive sense). In addition, as used herein, the term "one or more" may be used to describe any feature, structure, or characteristic of the singular, or may be used to describe some combination of features, structures, or characteristics. However, it should be noted that this is merely an illustrative example and the claimed subject matter is not limited to this example. In addition, if used in an associative list (such as A, B, or C), the term "at least one of..." may be interpreted to mean any combination of A, B, and / or C, such as A, B, C, AB, AC, BC, AA, AAB, ABC, AABBCCC, etc.

[0063] References throughout this specification to "one example," "an example," "some examples," or "exemplary implementations" mean that the particular features, structures, or characteristics described in conjunction with the features and / or examples may be included in at least one feature and / or example of the claimed subject matter. Thus, phrases appearing throughout the specification in "one example," "an example," "some examples," or "in some implementations," or other similar phrases, do not necessarily all refer to the same features, examples, and / or limitations. Furthermore, these particular features, structures, or characteristics may be combined in one or more examples and / or features.

[0064] In some specific implementations, operation or processing may involve physical manipulation of physical quantities. Typically, but not necessarily, such quantities may take the form of electrical or magnetic signals that can be stored, transmitted, combined, compared or otherwise manipulated. Mainly for reasons of common use, it has been proven that such signals are sometimes convenient to refer to bits, data, values, elements, symbols, characters, items, numbers, numerical values, etc. However, it should be understood that all of these or similar terms should be associated with appropriate physical quantities and are merely convenient labels. Unless otherwise specifically stated, as is apparent from the discussion herein, it should be understood that throughout this specification, discussions using terms such as "processing", "calculation", "calculation", "determination" refer to the actions or processes of specific devices (such as special-purpose computers, special-purpose computing devices or similar special-purpose electronic computing devices). In the context of this specification, therefore, a special-purpose computer or similar special-purpose electronic computing device is capable of manipulating or transforming a signal of a physical electronic or magnetic quantity that is usually represented as a memory, register, or other information storage device, a sending device, or a display device of the special-purpose computer or similar special-purpose electronic computing device.

[0065] In the above detailed description, numerous specific details are set forth to provide a thorough understanding of the claimed subject matter. However, those skilled in the art will appreciate that the claimed subject matter may be practiced without these specific details. In other instances, methods and devices known to those of ordinary skill in the art are not described in detail to avoid obscuring the claimed subject matter. Therefore, the claimed subject matter is intended not to be limited to the specific examples disclosed, but rather the claimed subject matter may also include all aspects falling within the scope of the appended claims and their equivalents.

Claims

1. A flexible busbar, comprising: a first busbar layer, the first busbar layer comprising a first bend and a first plurality of busbar segments, the first bend being located between first busbar segments of the first plurality of busbar segments; and A second busbar layer, the second busbar layer is coupled to the first busbar layer; the second busbar layer comprises a second bend and a second plurality of busbar segments, the second bend is located between second busbar segments in the second plurality of busbar segments, wherein: The first plurality of bus sections are substantially co-linear with the second plurality of bus sections; and The second bend is substantially parallel to the first bend.

2. The flexible busbar according to claim 1, wherein: The first bends are biased to spread the first busbar segments away from each other; and The second bends are biased to spread the second bus-segments away from each other.

3. The flexible busbar according to claim 2, wherein: The first bends are biased to spread the first busbar segments away from each other in a first direction; and The second bends are biased to spread the second bus-segments away from each other along the first direction.

4. The flexible busbar according to claim 3, wherein: The first busbar layer includes a third bend, the third bend being located between a first intermediate busbar segment in the first busbar segment and a first transverse busbar segment in the first plurality of busbar segments; The second busbar layer includes a fourth bend located between a second intermediate busbar segment in the second busbar segment and a second transverse busbar segment in the second plurality of busbar segments; The third bend is biased to cause the first intermediate bus-segment and the first transverse bus-segment to unfold in a second direction, the second direction being different from the first direction; and The fourth bend is biased to cause the second intermediate bus-segment and the second transverse bus-segment to unfold along the second direction. The flexible busbar according to claim 4 , wherein the second direction is opposite to the first direction.

6. The flexible busbar according to claim 4, wherein: The first busbar layer includes a fifth bend located between a third intermediate busbar segment in the first busbar segment and a third transverse busbar segment in the first plurality of busbar segments; The second busbar layer includes a sixth bend located between a fourth intermediate busbar segment in the second busbar segment and a fourth transverse busbar segment in the second plurality of busbar segments; The first bend is placed between the third bend and the fifth bend along the first busbar layer; and The second bend is placed between the fourth bend and the sixth bend along the first busbar layer.

7. The flexible busbar of claim 1, wherein the first bend and the second bend are offset from each other. The flexible busbar according to claim 1 , wherein the first bent portion and the second bent portion overlap. 9 . The flexible busbar of claim 1 , wherein the first bend and the second bend comprise a first arc shape.

10. The flexible busbar according to claim 9, wherein: The first busbar layer includes a third bend, and the second busbar layer includes a fourth bend; The third curved portion and the fourth curved portion include a second arc shape; and The first arc shape has a larger radius than the second arc shape.

11. A battery pack, comprising: a first battery unit; a second battery unit; and A flexible busbar electrically coupling the first battery cell and the second battery cell and disposed between the first battery cell and the second battery cell, the flexible busbar comprising busbar segments and preformed bends, the preformed bends being located between the busbar segments, wherein: The first battery cell is placed on the second battery cell, and the busbar sections overlap each other around the pre-formed bend in a closed state; and The flexible busbar is configured to deploy the first and second battery cells and the busbar segments away from each other to an open state. 12 . The battery pack of claim 11 , wherein in the open state, the first battery cell and the second battery cell are placed transversely to each other, and the busbar segments are spread transversely to each other around the preformed bend. 13 . The battery pack of claim 11 , further comprising a battery management unit coupled to the first battery cell and the second battery cell. The battery pack of claim 11 , wherein the busbar segments are substantially parallel to each other. 15 . The battery pack according to claim 11 , wherein the first battery cell and the second battery cell define a gap therebetween. 16 . The battery pack of claim 11 , wherein the flexible bus bar is placed between the first battery cell and the second battery cell.

17. The battery pack according to claim 16, The battery pack further includes a third battery cell; and The first battery cell is placed between the third battery cell and the second battery cell.

18. A method of assembling a battery pack, the method comprising: electrically coupling a flexible busbar to the first battery cell, the flexible busbar comprising busbar segments and preformed bends located between the busbar segments; electrically coupling the flexible busbar to a second battery cell, the first battery cell and the second battery cell being positioned transversely to each other, and the busbar segments being deployed transversely to each other around the preformed bend; as well as The flexible bus bar is bent at the preformed bending portion along the flexible bus bar to place the first battery cell on the second battery cell.

19. The method according to claim 18, further comprising: The flexible bus bar is bent at a second bent portion to place the first battery cell and the second battery cell closer to each other.

20. The method of claim 18, wherein the flexible bus bar is placed between the first battery cell and the second battery cell.

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