Multilayered flexible battery interconnects and methods of fabricating thereof

A multilayered flexible battery interconnect for interconnecting batteries in a battery pack, the multilayered flexible battery interconnect comprising:

• a first insulating layer;
• a second insulating layer comprising a support tab;
• a first conductive layer, disposed between the first insulating layer and the second insulating layer and directly interfacing the first insulating layer;
• and
• a second conductive layer, disposed between and directly interfacing each of the first conductive layer and the second insulating layer, wherein:
• the first conductive layer is thicker than the second conductive layer,
• the second conductive layer comprises a plurality of flexible tabs extending past the first conductive layer for connecting to the batteries,
• the support tab supports one of the plurality of flexible tabs at least before connecting to the batteries, and
• while connecting to the batteries, the one of the plurality of flexible tabs is configured to adhere to the support tab while the support tab is configured to separate from the remaining portion of the second insulating layer, or the one of the plurality of flexible tabs is configured to adhere to the support tab while the support tab is configured to bend out-of-plane relative to the remaining portion of the second insulating layer;
• and
• a voltage trace formed from a third conductive layer, wherein:
• the second insulating layer extends between the third conductive layer and the second conductive layer and comprises a second-insulating layer opening,
• the voltage trace is connected to the second conductive layer through the second-insulating layer opening,
• the second conductive layer is connected to the first conductive layer, and
• the first conductive layer forms bus bars such that one of the bus bars is electrically connected to the voltage trace.