Abstract: A framed lithium battery cell group includes a first frame member (20) and a second frame member (30). The frame members are locked together, clamping the lithium battery cell pack (10) on the seal edge surfaces (13, 16), thereby providing structural rigidity and protection from damage due to handling and vibration. Each of the frame members (20, 30) has multiple pins (25) and sockets (26) on the side opposite the clamping surface (33) to facilitate aligning and stacking multiple lithium battery cell pack and frame assemblies to form a lithium battery cell group (50). Each of the frame members (20, 30) include a buss bar capture feature (22, 32) having a bus bar (40) inserted therein for electrically connecting all of the terminals for a given lithium battery pack group to the buss bar (40).

Abstract: A process for physically bonding two parts to each other is disclosed. In addition, a process for forming electrical connections have a low resistance is disclosed. The process is generally applicable to the joining of two parts each formed from a metal, an alloy, or a combination thereof. The process finds special use in the formation of multi-celled batteries. The process involves placing two parts or electrical conductors in contact with each other and then bonding them to each other using a kinetic spray process and powder particles. In formation of a multi-celled battery the particles are preferably electrically conductive. The process enables for rapid and cost effective formation of a physical connection. In addition, the connection can have an electrical resistance of less than about 0.5 milli Ohms and strength equal or greater than ultrasonic welding.

Abstract: A battery assembly is designed to include a plurality of cells positioned parallel to each other. A frame including end supports position the cells appropriately. Each of the cells includes a first terminal and a second terminal. Two buses are positioned over all of the first terminals and all of the second terminals. Each of the buses includes slots allowing the terminals to extend therethrough. Once through, the terminals are bent over the bus bar. A slide is then positioned over the terminals protecting the terminals and maintaining the terminals in electrical contact with each other. This battery assembly allows more than three cells to be connected to each other and is versatile enough to allow the removal of certain cells to enhance the airflow through the battery assembly.