Corrugated foil connecting piece for battery

Abstract

Some embodiments disclosed herein relate to battery cells with corrugated foil tabs. Some embodiments may include a battery cell including a cathode, an anode, and a corrugated foil tab coupled to the cathode or the anode, where the corrugated foil tab has a length in a first plane, includes alternating peaks and valleys along the length of the corrugated foil tab in a second plane, and has a width in a third plane, and wherein the first plane, the second plane and the third plane are orthogonal to each other. Other embodiments may be disclosed or claimed.

Description

Technical Field

[0001] This disclosure relates to battery cells. In particular, embodiments of this disclosure relate to battery cells having corrugated foil tabs. Background Technology

[0002] Batteries are increasingly used in a variety of systems, from mobile computing devices to vehicles with electric motors. Such batteries can have multiple cells, each including a cathode and an anode separated by separators. Each cell typically includes a foil extending from the cathode and another foil extending from the anode, with multiple foils from the cathode and anode connected to a common lead tab.

[0003] In addition, embodiments of this disclosure provide reinforced contacts connected to the cell to help absorb shocks and vibrations and prevent unwanted failure modes such as increased cell resistance, additional heat generation, and the generation of unwanted byproducts that may lead to battery thermal runaway. Summary of the Invention

[0004] In one exemplary embodiment, a battery is provided. The battery includes a cathode, an anode, and a corrugated foil tab coupled to the cathode or the anode. The corrugated foil tab has a length in a first plane, includes alternating peaks and valleys along the length of the corrugated foil tab in a second plane, and has a width in a third plane. The first plane, the second plane, and the third plane are orthogonal to each other.

[0005] In addition to one or more features described herein, the corrugated foil is a first corrugated foil connected to the cathode, and the battery cell also includes a second corrugated foil connected to the anode.

[0006] In addition to one or more features described herein, the first corrugated foil tab is connected to the cathode at a first end of the first corrugated foil tab and to the first lead tab at a second end of the first corrugated foil tab, the first end of the first corrugated foil tab being opposite to the second end of the first corrugated foil tab.

[0007] In addition to one or more features described herein, the first corrugated foil tab includes an insulating coating on a first end of the first corrugated foil tab.

[0008] In addition to one or more of the features described herein, insulating coatings include polymeric and ceramic materials.

[0009] In addition to one or more of the features described herein, the insulating coating has a thickness of approximately 5 micrometers to 40 micrometers.

[0010] In addition to one or more features described herein, the first corrugated foil splice includes a polymer coating on a second end of the first corrugated foil splice, the polymer coating comprising one or more of the following: thermoplastic, polytetrafluoroethylene (PTFE), polyvinyl chloride (PVC), polyurethane, acrylonitrile-butadiene rubber (NBR), polytetrafluoroethylene / butyl rubber blend, nylon-6 / polypropylene blend, and urethane / acrylate interpenetrating polymer network.

[0011] In addition to one or more features described herein, the polymer coating on the second end of the first corrugated foil has a thickness of approximately 1 micrometer and 2 micrometers.

[0012] In addition to one or more features described herein, the second corrugated foil tab is connected to the anode at a first end of the second corrugated foil tab and to the second lead tab at a second end of the second corrugated foil tab, the first end of the second corrugated foil tab being opposite to the second end of the second corrugated foil tab.

[0013] In addition to one or more of the features described herein, the corrugated foil sheet comprises copper and at least one of the following: about 1% to 2% tin by weight, about 0.1% to 0.2% zinc by weight, and about 0.2% to 0.5% magnesium by weight.

[0014] In addition to one or more of the features described herein, the corrugated foil sheet comprises aluminum and at least one of the following: about 0.1% to 0.4% by mass of iron and about 0.1% to 0.5% by mass of silicon.

[0015] In addition to one or more features described herein, the battery cells have a pouch cell design, a prismatic cell design, or a cylindrical cell design.

[0016] In addition to one or more features described herein, the battery cell has a prismatic cell design in which corrugated foil tabs are directly connected to the cathode or anode without any intermediate connection structure.

[0017] In addition to one or more features described herein, the battery cell has a prismatic cell design, and wherein the corrugated foil tabs are connected to the cathode or anode via non-corrugated tabs extending from the cathode or anode.

[0018] In addition to one or more features described herein, the battery has a cylindrical cell design in which corrugated foil tabs are directly connected to the cathode or anode without any intermediate connecting structures.

[0019] In addition to one or more features described herein, the battery cell has a cylindrical cell design in which a corrugated foil is connected to the cathode or anode at a first end of the corrugated foil, and the corrugated foil is connected to the cap of the cylindrical cell at a second end of the corrugated foil, wherein the first end of the corrugated foil is opposite to the second end of the corrugated foil.

[0020] In addition to one or more features described herein, the peaks and valleys of the corrugated foil sheet have angular cross sections in the second plane, trapezoidal cross sections in the second plane, or a combination of angular and trapezoidal cross sections in the second plane.

[0021] In addition to one or more features described herein, the peaks and valleys of the corrugated foil splice have symmetrical or asymmetrical cross-sections in the second plane.

[0022] In another exemplary embodiment, a system is provided. The system includes a battery cell comprising a cathode, an anode, and a corrugated foil tab coupled to the cathode or anode. The corrugated foil tab has a length in a first plane, includes alternating peaks and valleys along its length in a second plane, and has a width in a third plane. The first, second, and third planes are orthogonal to each other.

[0023] In another exemplary embodiment, a vehicle is provided. The vehicle includes an electric motor and a battery pack coupled to the electric motor, the battery pack including battery cells. Each battery cell includes a cathode, an anode, and a corrugated foil tab coupled to the cathode or anode. The corrugated foil tab has a length in a first plane, includes alternating peaks and valleys along its length in a second plane, and has a width in a third plane. The first, second, and third planes are orthogonal to each other.

[0024] The above-described features and advantages, as well as other features and advantages of this disclosure, will become apparent when taken in conjunction with the accompanying drawings and the following detailed description. Attached Figure Description

[0025] Other features, advantages, and details appear by way of example only in the following detailed description, which refers to the accompanying drawings, wherein:

[0026] Figure 1 A diagram of a vehicle used in conjunction with one or more embodiments of this disclosure;

[0027] Figure 2A This is a side view illustrating an exemplary electrode stack design within a battery cell according to an embodiment of the present disclosure;

[0028] Figure 2B This illustrates an embodiment according to the present disclosure. Figure 2AAn isometric view of an exemplary electrode stacking design;

[0029] Figure 2C This is a diagram illustrating an example of connecting a foil to a battery cell according to an embodiment of the present disclosure;

[0030] Figure 2D This is a diagram illustrating another example of connecting foil tabs to a battery according to an embodiment of the present disclosure;

[0031] Figure 3A This is a diagram illustrating the connection between the foil tabs and the lead tabs according to an embodiment of the present disclosure;

[0032] Figure 3B This illustrates an embodiment according to the present disclosure. Figure 3A Another view of the connection between the foil tabs and the lead tabs;

[0033] Figure 4 A diagram illustrating an exemplary configuration of a prismatic battery cell design according to various embodiments is shown;

[0034] Figure 5A These are diagrams illustrating the configurations of cylindrical battery cells designed according to various embodiments;

[0035] Figure 5B This is a diagram of another configuration of a cylindrical battery cell design according to various embodiments;

[0036] Figure 6 This is a side view of an alternative corrugated foil splice construction according to one or more embodiments of the present disclosure; and

[0037] Figure 7 Examples of the dimensions and geometry of corrugated foil tabs according to various embodiments are shown. Detailed Implementation

[0038] The following description is exemplary in nature only and is not intended to limit this disclosure, its application, or use. It should be understood that throughout the drawings, corresponding reference numerals denote the same or corresponding parts and features.

[0039] According to exemplary embodiments, a battery cell with reinforced foil tabs is provided. In some embodiments, corrugated foil tabs may be attached to the electrode stack or electrode roll of the battery cell, specifically the cathode, anode, or both, to help provide improved flexibility and strain relief in the tabs, preventing tearing of the tabs due to impact or impact during manufacturing or operation. In some embodiments, the corrugated foil tabs may include a polymer coating to further help provide damping to further reduce impact and vibration. In this way, embodiments of this disclosure provide more robust and durable battery cells that are less susceptible to failures caused by torn or damaged tabs, including increased cell resistance, additional heat generation, and the generation of byproducts from the electrolyte in the cell. In some embodiments, corrugated lead tabs may be attached to the corrugated foil tabs of the cathode, anode, or both of the cathode and anode of the battery cell electrode stack to further provide flexibility and strain relief in the tabs. This helps prevent the tabs from tearing due to impact or impact during manufacturing or operation.

[0040] Figure 1 Figures are provided of a vehicle 100 used in conjunction with one or more embodiments of the present disclosure. The vehicle 100 includes a charging port 102, a battery 104, and an electric motor 106. In one embodiment, the vehicle 100 is a hybrid vehicle utilizing both an internal combustion engine and an electric motor. In another embodiment, the vehicle 100 is an electric vehicle utilizing only the electric motor. In an exemplary embodiment, the vehicle 100 is configured to be connected via the charging port 102 to a high-voltage power source (i.e., a voltage source of at least 200 volts (V)) for charging the battery 104. The electric motor 106 is configured to receive power from the battery 104 to provide propulsion for the vehicle 100.

[0041] Figure 2A This is a side view illustrating an exemplary battery cell design according to an embodiment of the present disclosure. In this example, battery cell 200 includes multiple bi-cells, each bi-cell including an anode / cathode pair. For example, bi-cell 210 includes an anode 220 and a cathode 230. Each anode and cathode has an active material coating on a foil used as a current collector. A foil tab has no active material coating and is located on one side of each anode and cathode. The foil tab is obtained by a grooving process. Each anode and cathode in battery cell 200 has a corresponding corrugated portion, which may be part of an integral extension of an existing foil tab, or (alternatively) an existing foil tab of the battery may be coupled to a separate and extended corrugated foil tab. For example, in bi-cell 210, anode 220 has an integral extension of corrugated foil tab 222, and cathode 230 has an integral extension of corrugated foil tab 232. Anode 220 and cathode 230 are further separated by an insulating layer 240. Figure 2B An isometric view of battery cell 200 and dual cells 210 is shown.

[0042] like Figure 2A As shown, the corrugated foil tab 232 coupled to the cathode 230 includes an insulating coated portion 234 near the edge of the cathode 230 to help prevent contact (and thus short circuit) between the anode 220 and the cathode 230. In this example, the cathode 230 is smaller than the anode 220 in all dimensions. In this example, there is no such corresponding insulating coating on the corrugated foil tab 222 coupled to the edge of the anode. In some embodiments, the insulating portion 234 may be part of the overall structure of the tab 232 without intermediate connecting structures. Alternatively, the insulating portion 234 may be a separate structure coupled to the tab 232 (e.g., via welding or riveting).

[0043] like Figure 2A and Figure 2B As shown, the corrugated foil tabs 222 and 232 may have length in a first plane (e.g., the x-plane), alternating peaks and valleys in a second plane (e.g., the y-plane), and width in a third plane (e.g., the z-plane), wherein the first, second, and third planes are orthogonal to each other in a three-dimensional configuration. The corrugated foil tabs 222 and 232 may have any suitable dimensions to provide sufficient mechanical strength and conduct current from the battery dual cell 210. In some embodiments, for example, the corrugated foil tabs 222 and 232 have a thickness in the range of about 5 μm to 200 μm.

[0044] The insulating coating on portion 234 may comprise a polymer (e.g., polyvinylidene fluoride or PVDF) binder and a ceramic (e.g., 10 wt% to 50 wt% alumina powder and / or 0.1 wt% to 3 wt% rare earth oxides). In some embodiments, the insulating coating at portion 234 may have a width of approximately 2.0-6.0 mm and a thickness of approximately 5-40 μm.

[0045] In some embodiments, corrugated foil tab 222 may include copper (e.g., having 99.9 wt% copper and 0.1 wt% phosphorus). In some embodiments, corrugated foil tab 232 may include aluminum (e.g., 99.0-99.95 wt% aluminum and 0.05-0.20 wt% copper). In some embodiments, corrugated foil tabs 222 and 232 may include copper alloys or aluminum alloys. For example, a copper alloy may include copper and one or more of the following components by mass percentage: 1.0-2.0% Sn, 0.1-0.2% Zn, and 0.2-0.5% Mg. In another example, an aluminum alloy may include aluminum and one or more of the following components by mass percentage: 0.1-0.4% Fe and 0.1-0.5% Si. In some embodiments, the corrugated foil tabs of this disclosure may include C110 (99.9% Cu). In some embodiments, the corrugated foil splice disclosed herein may include Al 1100 (99-99.95% Al, Cu 0.2-0.6%, Fe ≤ 0.4%, Mn ≤ 0.15%, Si ≤ 0.4%, Ti ≤ 0.15%).

[0046] Corrugated foil tabs can be coupled to the cathode and anode of the battery cell in various configurations according to embodiments of this disclosure. The corrugated foil can be grouped into one or more sets. For example, Figure 2C This is a diagram illustrating an example of connecting foil sheets to a battery cell according to an embodiment of the present disclosure. In this example, battery cell 250 shows multiple cathodes connected to various corrugated foil sheets. Battery cell 250 has corresponding corrugated portions, which may be part of an integral extension of an existing foil sheet, or the existing foil sheets of the cell may be connected to individual and extending corrugated foil sheets. For example, corrugated foil sheet 232a is an integral extension of the foil sheets of cathodes 230a, 230b, and 230c at a first end, and extends to lead sheet 238 at a second end (the first and second ends are opposite to each other). The existing foil sheets of cathodes 230a, 230b, and 230c may be corrugated together at once. Figure 2C One advantage of the configuration shown is that it simplifies the implementation of the corrugated tabs by reducing the total number of foil tab layers used for corrugation. Additionally, in some embodiments, some foil tabs may be corrugated while others may be non-corrugated, to provide corrugated tabs, for example, in portions of the battery cell that tend to experience higher stresses than other parts of the battery.

[0047] Figure 2DThis is a diagram illustrating another example of attaching foil sheets to a battery cell 260 according to an embodiment of the present disclosure. In this example, the co-corrugated foil tab 262 is an integral extension of all the plurality of cathode foil tabs and is further connected to the lead tab 238. Among other things, this configuration can help improve the efficiency of manufacturing battery cells according to embodiments of the present disclosure by minimizing the corrugations formed by the tab 262.

[0048] Figure 3A This is a diagram illustrating the connection between a foil patch and a lead patch according to an embodiment of the present disclosure. In this example, FIG. 300 shows a corrugated foil patch 305 having a polymer-coated surface 310 and an uncoated surface 320 (e.g., from...). Figure 2A The corrugated foil tabs 222, 232) are shown in portions. A lead tab 330 is also shown. Foil tabs 305 are joined at 340 such that the uncoated surface 320 is coupled to the lead tab 330 as shown. In some embodiments, the lead tabs coupled to the corrugated foil tabs (e.g., lead tab 330) may also be corrugated and / or include coated and uncoated portions.

[0049] Figure 3B This illustrates an embodiment according to the present disclosure. Figure 3A Figure 350 shows another view of the connection between the foil tab and the lead tab. In this example, the positioning of the lead tab 330 relative to the solder area 360 is shown.

[0050] exist Figure 3A and Figure 3B In the example shown, the coating on portion 310 can act as a damper to help eliminate or reduce vibrational energy through friction. In some embodiments, the coating material may include polymers (such as thermoplastics) or polymer composites. Examples of polymers that can be used on the coated surface 310 include polytetrafluoroethylene (PTFE), polyvinyl chloride (PVC), polyurethane, acrylonitrile-butadiene rubber (NBR), PTFE / butyl rubber blends, nylon-6 / polypropylene blends, and polyurethane / acrylate interpenetrating polymer networks.

[0051] In some embodiments, the coated surface 310 may comprise an elastomer or other amorphous thermoplastic with a glass transition temperature below room temperature. In some embodiments, the coated surface may comprise a polymer blend or interpenetrating network. For example, in one embodiment, the coating material may comprise a polymer composition of polyvinyl chloride (PVC) and acrylonitrile-butadiene rubber (NBR) having a 50:50 or 30:70 ratio. In some embodiments, the coating material on the coated surface 310 may have a thickness in the range of about 1-2 μm. Figure 3A and Figure 3BAs shown, the coating surface 310 can begin at the edge of the electrode and end at the edge of the patch soldering area 360. Furthermore, this helps ensure that the coating does not interfere with soldering the foil patch 305 to the lead patch 330.

[0052] The corrugated foil tabs described in this article can be used in conjunction with a variety of different battery cell designs. For example, Figure 4 This is a diagram illustrating the configuration of a prismatic battery cell design according to various embodiments. In this example, battery cell 400 includes corrugated foil tabs 222, 232, which may be integral structures extending from or connected to the anode and cathode of battery cell 400, respectively. Battery cell 400 in this example is a "roll" structure 407 enclosed in a can 405. In this example, the roll structure 407 is a flat-winded roll structure, but embodiments of this disclosure may operate in combination with stacked roll structures or any other suitable battery design configuration. Insulating layer 420 separates the corrugated foil tabs 222, 232 to prevent them from short-circuiting, and the corrugated foil tabs 222, 232 are coupled to battery head 410.

[0053] As described above, the corrugated foil tabs 222 and 232 can be an integral structure extending from the existing foil tabs from the anode and cathode, or they can be joined (e.g., by welding) to tabs extending from the anode and cathode (which may be corrugated or non-corrugated themselves). In this example, the corrugated foil tabs 222 and 232 are joined to an extended foil tab directly connected to the cell holder 410, but in an alternative embodiment, the corrugated foil tabs 222 and 232 can be joined to the anode and cathode on opposite or orthogonal sides of the battery cell 400.

[0054] In another example, Figure 5A This is a diagram illustrating the configuration of a cylindrical battery cell design according to various embodiments. Here, the battery cell 500 includes a cathode layer 530 having corrugated foil cathode tabs (e.g., tabs 532) extending therefrom. The battery cell 500 also includes an anode layer 520 having corrugated foil anode tabs (e.g., tabs 522) extending therefrom. The cathode layer 530 and the anode layer 520 are wound together into a roll structure 540, with a separator layer 510 present therebetween. The roll structure 540 is enclosed within a can 545. An internal lead 550 is connected at one end to a cathode electrode and at the other end to a cap 555.

[0055] In some embodiments, the internal lead 550 may be an integral extension of the corrugated foil patch (without any intermediate connecting structure) or a separate component connected to the corrugated foil patch. In some embodiments, the internal lead 550 may be a separate non-corrugated structure connected to the corrugated foil patch.

[0056] Figure 5B This is a diagram illustrating another configuration of a cylindrical battery cell design according to various embodiments. In this example, battery cell 560 includes a cathode layer 565 and an anode layer 570, which are wound together in a roll structure 575, with a separator layer 567 present therebetween. In this example, cylindrical battery cell 560 includes a... Figure 5A The design shown has a relatively larger number of corrugated foil tabs, and the gap between each tab is greater than that between the two tabs. Figure 5A The design in this example is much smaller. In this example, corrugated foil tabs extending from cathode layer 565 (e.g., tab 532) and anode layer 570 (e.g., tab 522) are rolled or welded to the top and bottom of can 545.

[0057] Figure 6 Side views of alternative corrugated foil patch constructions according to one or more embodiments of the present disclosure are shown. In this example, constructions 610-650 show side views (e.g., in the xy plane) of exemplary corrugated constructions. For example, construction 610 shows an angled corrugated pattern where alternating peaks and valleys are symmetrical and the peaks and valleys have an angle of less than 90 degrees. Construction 620 shows a trapezoidal corrugated construction where alternating peaks and valleys have extended flat portions. Construction 630 shows an example of a mixed angular and trapezoidal construction where the peaks are angular and the valleys are trapezoidal.

[0058] Embodiments of this disclosure may also utilize other corrugated configurations. For example, configuration 640 shows a corrugated configuration with peaks and valleys that are more closely angled than configuration 610, and wherein the peaks and valleys are tilted (tilted to the right in this example). The geometry of the corrugated foil tabs used in conjunction with embodiments of this disclosure may be symmetrical (as shown in configurations 610 and 620) or asymmetrical, as shown in configuration 650, wherein the amplitudes of the alternating peaks and valleys are not the same.

[0059] In some embodiments, asymmetrical corrugations can be used so that various empty spaces within the cell can accommodate various corrugated structures. As an example, the end of a corrugated pattern with a reduced size or height (as shown in the right portion of configuration 650) can be advantageously used at the edge of the welding area, while the other end of a corrugated pattern with a relatively large size or height (as shown in the left portion of configuration 650) can be used at the electrode edge, where the large empty space can accommodate the corrugated structure.

[0060] Figure 7 Examples of the dimensions and geometries of corrugated foil sheets according to various embodiments are shown. In this example, a figure from... Figure 6The periodic unit wave pattern in configuration 610. Here, the foil 710 before corrugation is shown as having an effective length L0 in a first plane (e.g., the x-plane) and a thickness T in a second plane (e.g., the y-plane). As described above, the foil 710 also has a width ( ) in a third plane (e.g., the z-plane). Figure 7 (Not shown in the diagram), wherein the first plane, the second plane, and the third plane are orthogonal to each other in a three-dimensional configuration. In some embodiments, the length L0 may be less than about 30 mm and may be configured based on the available space within the cell of a particular battery. The variables associated with the periodic unit wave pattern in configuration 610 are as follows:

[0061] h: Height of a periodic unit wave

[0062] α: Angle of a periodic unit wave

[0063] a: Half the wavelength in the corrugated foil splice: a = h * tan(α / 2)

[0064] La: 1 / 4 of the length of a periodic unit wave: La = h / cos(α / 2)

[0065] n: The number of periodic unit waves: n = L0 / (2a)

[0066] L: Total length of the foil splices in the corrugated section: L=(2La)*n

[0067] For example, for Figure 7 The symmetrically angled corrugated foil splice 610 shown has an effective length of 5 mm, a unit wave height of 250 μm, a unit wave angle of 60°, and the number of unit waves can be calculated as 8. The actual length of the foil splice can be calculated as 10 mm. Figure 7 The corrugated pattern is analogous to a sine wave, and the band gap width of the wave is therefore controlled by the height (h) and angle (α) of the periodic unit wave. The number, height, angle, and band gap of the periodic corrugations, as well as the total length of the corrugated foil splice, can be determined for manufacturing and quality control.

[0068] For asymmetric or irregular corrugations in foil splices, such as Figure 6As shown in configuration 650, the actual length of the foil tab can be estimated based on a similar symmetrical triangular corrugation and then adjusted based on the available unused space within the cell. Another way to estimate the actual length of the foil tab can be based on energy absorption measurements during shock or vibration testing. For example, in some embodiments, a Cu foil with a corrugated structure (5 mm displacement) according to embodiments of this disclosure can increase energy absorption by more than 500%. Similarly, an Al foil tab with a corrugated structure (4 mm displacement) according to embodiments of this disclosure can increase energy absorption by more than 450%. Therefore, if a 10-fold increase in energy absorption is required, an additional 8-10 mm length of Cu or Al foil may be needed. The bandgap width can be estimated based on the effective length and actual length of each foil tab. In some embodiments, for corrugated lead tabs, the actual length of the lead tab can be similarly estimated based on energy absorption requirements.

[0069] The term “a” does not indicate a limitation of quantity, but rather that at least one of the referenced items is present. Unless the context clearly indicates otherwise, the term “or” means “and / or”. Throughout the specification, reference to “aspect” means that a particular element described in connection with that aspect (e.g., a feature, structure, step, or characteristic) is included in at least one aspect described herein and may or may not be present in other aspects. Furthermore, it should be understood that the described elements may be combined in any suitable manner in the aspects.

[0070] When an element, such as a layer, film, region, or substrate, is referred to as being “on” another element, it can be directly on the other element, or there may be intermediate elements present. Conversely, when an element is referred to as being “directly” on another element, there are no intermediate elements present.

[0071] Unless otherwise stated herein, all test standards are the most recent standards in effect as of the date of filing of this application, or, if priority is claimed, the date of filing of the earliest priority application in which a test standard appears.

[0072] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0073] While the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from its scope. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of this disclosure without departing from the basic scope of this disclosure. Therefore, it is intended that this disclosure be limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A battery cell, comprising: cathode; anode; as well as A corrugated foil tab coupled to the cathode or the anode, wherein the corrugated foil tab has a length in a first plane, comprises alternating peaks and valleys along the length of the corrugated foil tab in a second plane, and has a width in a third plane, and wherein the first plane, the second plane, and the third plane are orthogonal to each other. 2 . The battery cell of claim 1 , wherein the corrugated foil is a first corrugated foil coupled to the cathode, the battery cell further comprising a second corrugated foil coupled to the anode.

3. The battery cell of claim 2, wherein the first corrugated foil tab is coupled to the cathode at a first end of the first corrugated foil tab and is coupled to a first lead tab at a second end of the first corrugated foil tab, the first end of the first corrugated foil tab being opposite to the second end of the first corrugated foil tab. 4 . The battery cell of claim 3 , wherein the first corrugated foil tab comprises an insulating coating on the first end of the first corrugated foil tab.

5. The battery cell of claim 4, wherein the insulating coating comprises a polymer and a ceramic material.

6. The battery cell of claim 4, wherein the insulating coating has a thickness of about 5 microns to 40 microns.

7. The battery cell of claim 3, wherein the first corrugated foil tab comprises a polymer coating on the second end of the first corrugated foil tab, the polymer coating comprising one or more of the following: thermoplastics, polytetrafluoroethylene, polyvinyl chloride, polyurethane, acrylonitrile-butadiene rubber, polytetrafluoroethylene / butyl rubber blends, nylon-6 / polypropylene blends, and urethane / acrylate interpenetrating polymer networks.

8. The battery cell of claim 7, wherein the polymer coating on the second end of the first corrugated foil tab has a thickness of approximately 1 micron and 2 microns.

9. The battery cell of claim 3, wherein the second corrugated foil is coupled to the anode at a first end of the second corrugated foil and to a second lead tab at a second end of the second corrugated foil, the first end of the second corrugated foil being opposite to the second end of the second corrugated foil. 10 . The battery cell according to claim 1 , wherein the battery cell has a pouch cell design, a prismatic cell design or a cylindrical cell design.

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