Abstract: A battery module is formed from a plurality of battery cells having top and bottom electrodes. Top and bottom collector plates overlay, and are electrically connected with, the battery cell top and bottom electrodes. The collector plates may be formed wholly or primarily from copper. Cell apertures may be formed within the collector plates overlying each cell, with collector arms extending into said apertures for connection with an underlying cell electrode. The collector arms may include a fusible link for each cell. A bridge collector plate may span subsets of cells, and include a module-level fusible link formed therein. A current concentrator, such as a dimple or depression, may be formed in a collector arm to facilitate resistance welding of the copper collector plates to underlying battery cells, which may include electrodes formed from steel or other material more resistive than the copper collector plates.

Abstract: A battery module is formed from a plurality of battery cells having top and bottom electrodes. Top and bottom collector plates overlay, and are electrically connected with, the battery cell top and bottom electrodes. The collector plates may be formed wholly or primarily from copper. Cell apertures may be formed within the collector plates overlying each cell, with collector arms extending into said apertures for connection with an underlying cell electrode. The collector arms may include a fusible link for each cell. A bridge collector plate may span subsets of cells, and include a module-level fusible link formed therein. A current concentrator, such as a dimple or depression, may be formed in a collector arm to facilitate resistance welding of the copper collector plates to underlying battery cells, which may include electrodes formed from steel or other material more resistive than the copper collector plates.