Abstract: Provided are flexible interconnect circuits comprising signal circuit elements. For example, a signal circuit element can be formed from the same metal sheet as a signal trace, thereby being monolithic with the signal circuit element. This integration of signal circuit elements into a flexible interconnect circuit reduces the number of additional operations and components (e.g., attaching external circuit elements). In some examples, a flexible interconnect circuit is used in a battery pack for interconnecting batteries while providing external terminals on the same side of the pack. Specifically, a flexible interconnect circuit comprises an interconnecting conductive layer (for connecting to batteries) and a return conductive layer, both extending between the first and second circuit edges. Each of these conductive layers comprises a corresponding external terminal at the first edge, while these layers are interconnected at the second edge.

Abstract: Provided are flexible interconnect circuit assemblies and methods of fabricating thereof. In some examples, a flexible interconnect circuit comprises multiple circuit portions, which are monolithically integrated. During the fabrication, some of these circuit portions are folded relative to other portions, forming a stack in each fold. For example, the initial orientation of these portions can be selected such that smaller sheets can be used for circuit fabrication. The portions are then unfolded into the final design configuration. In some examples, the assembly also comprises a bonding film and a temporary support film attached to the bonding film such that the two circuit portions at least partially overlap with the bonding film and are positioned between the bonding film and temporary support film. In some examples, at least some circuit portions extend past the boundary of the bonding film and are coupled to connectors.

Abstract: Provided are flexible interconnect circuit assemblies and methods of fabricating thereof. In some examples, a flexible interconnect circuit comprises multiple circuit portions, which are monolithically integrated. During the fabrication, some of these circuit portions are folded relative to other portions, forming a stack in each fold. For example, the initial orientation of these portions can be selected such that smaller sheets can be used for circuit fabrication. The portions are then unfolded into the final design configuration. In some examples, the assembly also comprises a bonding film and a temporary support film attached to the bonding film such that the two circuit portions at least partially overlap with the bonding film and are positioned between the bonding film and temporary support film. In some examples, at least some circuit portions extend past the boundary of the bonding film and are coupled to connectors.

Abstract: Provided are flexible interconnect circuit assemblies and methods of fabricating thereof. In some examples, a flexible interconnect circuit comprises multiple circuit portions, which are monolithically integrated. During the fabrication, some of these circuit portions are folded relative to other portions, forming a stack in each fold. For example, the initial orientation of these portions can be selected such that smaller sheets can be used for circuit fabrication. The portions are then unfolded into the final design configuration. In some examples, the assembly also comprises a bonding film and a temporary support film attached to the bonding film such that the two circuit portions at least partially overlap with the bonding film and are positioned between the bonding film and temporary support film. In some examples, at least some circuit portions extend past the boundary of the bonding film and are coupled to connectors.

Abstract: Systems and methods for a battery module including a subassembly that can include cells electrically connected to form a group; and groups of cells electrically connected to form the subassembly. The subassembly can include a lower cell carrier and an upper cell carrier configured to retain a thermally insulating material, the group of cells disposed between the upper and lower cell carriers, cell alignment and retention features integrally formed with one or more of: lower or upper cell carriers, means for inhibiting propagation of thermal runaway, a current collector comprising two or more conductive regions; and positive and negative terminals electrically connected to the two or more conductive regions, respectively, to form positive and negative terminals of battery module.

Abstract: An improved battery module and methods of assembly are disclosed. A battery module may include carriers for holding battery cells via interference fit. The carriers may include a busbar with a stamped fusible link between each battery cell and the busbar. The battery module may be held together via interference fit, laser welding, and friction welding. A method of assembly may electrically and mechanically connect battery cells by laser welding stamped fusible links within a busbar. The method may further enclose the battery cells within a case and create a seal between the lid and case using friction welding.

Abstract: A motor vehicle seat restraint system may include a tongue or buckle and an electrical component carried thereby, an elongated restraint web coupled to the tongue or buckle, the restraint web having a first side and a second side opposite the first side, an outer surface between the first and second sides and an inner surface opposite the outer surface, a channel member coupled to and between the inner and outer surfaces of the restraint web adjacent to the first side of the restraint web and extending along at least a portion of a length thereof, the channel member and the first side of the restraint web defining a passageway therebetween, and one or more electrical wires operatively coupled to the electrical component and extending into and through the passageway such that the one or more electrical wires ride within the channel member along-side the restraint web.

Abstract: A motor vehicle seat restraint system may include a tongue or buckle and an electrical component carried thereby, an elongated restraint web coupled to the tongue or buckle, the restraint web having a first side and a second side opposite the first side, an outer surface between the first and second sides and an inner surface opposite the outer surface, a channel member coupled to and between the inner and outer surfaces of the restraint web adjacent to the first side of the restraint web and extending along at least a portion of a length thereof, the channel member and the first side of the restraint web defining a passageway therebetween, and one or more electrical wires operatively coupled to the electrical component and extending into and through the passageway such that the one or more electrical wires ride within the channel member along-side the restraint web.

Abstract: The present disclosure relates to a method of manufacturing a lead-acid battery, the method including: (i) extending a current collector from an end of a cell pack; and (ii) laser-welding a bus bar to the current collector.