Abstract: A battery cell assembly includes an electrode structure, a case that houses the electrode structure, and a wet-applied electrical sealant that covers at least a portion of at least one edge of the case. A battery cell electrical sealing method includes applying a liquid to at least one edge of a battery cell, and curing the liquid on the at least one edge to electrically seal the at least one edge.

Abstract: Battery tabs can be disposed through slots of a busbar and then deformed over a portion of the busbar. The battery tabs can be affixed to the busbar after they are deformed. The resulting busbar assembly can include a recess shaped to complement a body suitable for deforming the battery tabs.

Abstract: A battery pack terminal shield assembly includes an anchoring section, a first terminal cap connected to the anchoring section, and a second terminal cap connected to the anchoring section. The anchoring section is configured to secure the first terminal cap and the second terminal cap relative to an array of traction battery pack.

Abstract: Busbar modules are provided for electrically connecting battery cells of a battery system for a traction battery pack. The busbar modules may include a scalable design for accommodating battery systems of all sizes and design requirements. An exemplary busbar module may include a busbar frame and a busbar system positionable relative to a grouping of battery cells by the busbar frame. The busbar system may include a negative terminal, a positive terminal, a plurality of short busbars, and a long busbar.

Abstract: An electrical connection system includes a first electrical contact, and a second electrical contact joined directly to the first electrical contact. The first electrical contact is configured to flex relative to the second electrical contact along a first axis, and configured to flex relative to the first electrical contact along a second axis.