Multi-stack battery cells with different tab lengths

Abstract

Some embodiments disclosed herein relate to a battery cell having a cell stack having different tab lengths. Some embodiments may include a first cell stack and a second cell stack adjacent to the first cell stack, the first cell stack including a first plurality of tabs extending from the first cell stack, the second cell stack including a second plurality of tabs extending from the second cell stack, where the second plurality of tabs is shorter than the first plurality of tabs. The weld plate may be welded to the first plurality of tabs and the second plurality of tabs without trimming the first plurality of tabs. Other embodiments may be disclosed or claimed.

Description

Technical Field

[0001] The present disclosure relates to battery cells. In particular, embodiments of the present disclosure relate to battery cells having a battery stack having different tab lengths. Background Art

[0002] Batteries are increasingly used in a variety of systems ranging from mobile computing devices to vehicles with electric motors. Some such batteries may have multiple battery cells, where each battery cell has two or more battery stacks, and each stack includes multiple layers. Each layer may have a cathode tab and an anode tab extending from the layer, where the tabs in the layers of some batteries have a substantially uniform length. Due to the length of the tabs, battery cells having a large number (e.g., 100 or more) of layers have the problem of welding the stacked tabs to the welding plate. In particular, during the welding process, a large number of tabs must typically be folded over the terminals of the battery, which helps to improve the efficiency of the welding process during battery assembly and increase the contact between the terminals and the electrodes.

[0003] However, in batteries having a large number of layers, portions of the tabs tend to extend beyond the weld plates when folded, requiring trimming of the extended portions, which can leave residual particles, increase electrical resistance due to the need for additional welding, and reduce the overall efficiency of the battery production process. Among other things, embodiments of the present disclosure provide battery modules having adjacent battery stacks having different tab lengths to avoid the need to trim the tabs of the batteries during the welding process, thereby helping to improve the efficiency and reliability of the battery module. Summary of the invention

[0004] In one exemplary embodiment, a battery cell is provided. The battery cell includes a first battery stack and a second battery stack adjacent to the first battery stack, the first battery stack including a first plurality of tabs extending from the first battery stack. The second battery stack includes a second plurality of tabs extending from the second battery stack, wherein the second plurality of tabs are shorter than the first plurality of tabs. The battery cell also includes a welding plate welded to the first plurality of tabs and the second plurality of tabs without trimming the first plurality of tabs.

[0005] In addition to one or more features described herein, the first plurality of tabs is a first plurality of cathode tabs, the second plurality of tabs is a second plurality of cathode tabs, and the welding plate is a first welding plate. The battery cell also includes a first plurality of anode tabs extending from the first battery stack and a second plurality of anode tabs extending from the second battery stack. The second plurality of anode tabs are shorter than the first plurality of anode tabs, and the battery cell includes a second welding plate that is welded to the first plurality of anode tabs and the second plurality of anode tabs without trimming the first plurality of anode tabs.

[0006] In addition to one or more features described herein, the first plurality of cathode tabs extend from a first end of the first battery stack, the second plurality of cathode tabs extend from a first end of the second battery stack, the first plurality of anode tabs extend from a second end of the first battery stack, the second plurality of anode tabs extend from a first end of the second battery stack, the first end of the first battery stack is opposite to the second end of the first battery stack, and the first end of the second battery stack is opposite to the second end of the second battery stack.

[0007] In addition to one or more features described herein, the first plurality of cathode tabs and the second plurality of cathode tabs include aluminum.

[0008] In addition to one or more features described herein, the first plurality of anode tabs and the second plurality of anode tabs include copper.

[0009] In addition to one or more features described herein, the first welding plate includes aluminum and the second welding plate includes copper.

[0010] In addition to one or more features described herein, the first plurality of tabs have a length between about 10 mm and 30 mm, and wherein the second plurality of tabs are between about 30%-50% of the length of the first plurality of tabs.

[0011] In another exemplary embodiment, a system includes a battery cell, the battery cell including a first battery stack and a second battery stack adjacent to the first battery stack, the first battery stack including a first plurality of tabs extending from the first battery stack. The second battery stack includes a second plurality of tabs extending from the second battery stack, and the second plurality of tabs are shorter than the first plurality of tabs. The battery cell also includes a welding plate welded to the first plurality of tabs and the second plurality of tabs without trimming the first plurality of tabs.

[0012] In addition to one or more features described herein, the first plurality of tabs is a first plurality of cathode tabs, the second plurality of tabs is a second plurality of cathode tabs, and the welding plate is a first welding plate. The battery cell also includes a first plurality of anode tabs extending from the first battery stack and a second plurality of anode tabs extending from the second battery stack. The second plurality of anode tabs are shorter than the first plurality of anode tabs. The battery cell also includes a second welding plate welded to the first plurality of anode tabs and the second plurality of anode tabs without trimming the first plurality of anode tabs.

[0013] In addition to one or more features described herein, the first plurality of cathode tabs extend from a first end of the first battery stack, the second plurality of cathode tabs extend from a first end of the second battery stack, the first plurality of anode tabs extend from a second end of the first battery stack, the second plurality of anode tabs extend from a first end of the second battery stack, the first end of the first battery stack is opposite to the second end of the first battery stack, and the first end of the second battery stack is opposite to the second end of the second battery stack.

[0014] In addition to one or more features described herein, the first plurality of cathode tabs and the second plurality of cathode tabs include aluminum.

[0015] In addition to one or more features described herein, the first plurality of anode tabs and the second plurality of anode tabs include copper.

[0016] In addition to one or more features described herein, the first welding plate includes aluminum and the second welding plate includes copper.

[0017] In addition to one or more features described herein, the first plurality of tabs have a length between about 10 mm and 30 mm, and wherein the second plurality of tabs are between about 30%-50% of the length of the first plurality of tabs.

[0018] In another exemplary embodiment, a vehicle includes an electric motor and a battery unit coupled to the electric motor. The battery unit includes a first battery stack and a second battery stack adjacent to the first battery stack, the first battery stack including a first plurality of tabs extending from the first battery stack. The second battery stack includes a second plurality of tabs extending from the second battery stack, and the second plurality of tabs are shorter than the first plurality of tabs. The battery unit also includes a welding plate welded to the first plurality of tabs and the second plurality of tabs without trimming the first plurality of tabs.

[0019] In addition to one or more features described herein, the first plurality of tabs is a first plurality of cathode tabs, the second plurality of tabs is a second plurality of cathode tabs, and the welding plate is a first welding plate, the battery cell further comprising a first plurality of anode tabs extending from the first battery stack and a second plurality of anode tabs extending from the second battery stack, wherein the second plurality of anode tabs are shorter than the first plurality of anode tabs. The battery cell further comprises a second welding plate welded to the first plurality of anode tabs and the second plurality of anode tabs without trimming the first plurality of anode tabs.

[0020] In addition to one or more features described herein, the first plurality of cathode tabs extend from a first end of the first battery stack, the second plurality of cathode tabs extend from a first end of the second battery stack, the first plurality of anode tabs extend from a second end of the first battery stack, the second plurality of anode tabs extend from a first end of the second battery stack, the first end of the first battery stack is opposite to the second end of the first battery stack, and the first end of the second battery stack is opposite to the second end of the second battery stack.

[0021] In addition to one or more features described herein, the first plurality of cathode tabs and the second plurality of cathode tabs include aluminum, and wherein the first plurality of anode tabs and the second plurality of anode tabs include copper.

[0022] In addition to one or more features described herein, the first welding plate includes aluminum and the second welding plate includes copper.

[0023] In addition to one or more features described herein, the first plurality of tabs have a length between about 10 mm and 30 mm, and wherein the second plurality of tabs are between about 30%-50% of the length of the first plurality of tabs.

[0024] The above features and advantages and other features and advantages of the present disclosure are apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0026] Figure 1 is a diagram of a vehicle for use in conjunction with one or more embodiments of the present disclosure;

[0027] Figure 2A is a diagram showing a battery cell stack having different tab lengths according to an embodiment of the present disclosure;

[0028] Figure 2B is another diagram showing a battery cell stack having different tab lengths according to an embodiment of the present disclosure; and

[0029] Figure 3 is a diagram illustrating examples of different battery tab lengths according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0030] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0031] According to an exemplary embodiment, a battery cell having an enhanced tab structure is provided. In some embodiments, the battery cell includes a first battery stack and a second battery stack adjacent to the first battery stack, the first battery stack including a first plurality of tabs extending from the first battery stack. The second battery stack includes a second plurality of tabs extending from the second battery stack, and the second plurality of tabs are shorter than the first plurality of tabs. The battery cell also includes a welding plate welded to the first plurality of tabs and the second plurality of tabs without trimming the first plurality of tabs.

[0032] In this way, embodiments of the present disclosure provide battery cells having multiple stacks with different tab lengths. A stacked structure having a large number of layers can be coupled to a common welding plate without having to trim any excess material from the tabs, thereby allowing battery modules containing such batteries to be assembled more efficiently and without the risk of damage due to residual particles left behind by trimming the tabs.

[0033] Figure 1 A diagram of a vehicle 100 for use in conjunction with one or more embodiments of the present disclosure is provided. 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 that utilizes both an internal combustion engine and an electric motor. In another embodiment, the vehicle 100 is an electric vehicle that utilizes only an electric motor. In an exemplary embodiment, the vehicle 100 is configured to be connected to a high voltage power source (i.e., a voltage source of at least 200 volts (V)) for charging the battery 104 via the charging port 102. The electric motor 106 is configured to receive power from the battery 104 to provide propulsion for the vehicle 100.

[0034] Figure 2A A battery cell stack with different tab lengths according to an embodiment of the present disclosure is shown. In this example, the known configuration 200 shows an example of a first battery stack 210 and a second battery stack 220 before and after being coupled to a welding plate 230. In the configuration 200, the battery stack 210 includes a plurality of tabs 212 extending from the battery stack 210, and the battery stack 220 also includes a plurality of tabs 222 extending from the battery stack 220. In the known configuration 200, the tabs 212 and 222 have substantially the same length, and when they are folded and connected to the welding plate 230, a portion of the tab extends beyond the edge of the welding plate 230 (at portion 215). This requires trimming of the portion at section 215 during production, increasing the complexity of assembling battery cells and modules using the stacks 210 and 220, and also introducing the risk that particles from the trimmed section 215 will be left behind to potentially damage the battery.

[0035] In contrast, in an embodiment of the present disclosure represented by configuration 250, the first battery stack 210 has a first plurality of tabs 255, and the second battery stack 220 has a second plurality of tabs 260, wherein the second plurality of tabs 260 are shorter than the first plurality of tabs 255. In configuration 250, the welding plate 230 is welded to the first plurality of tabs 255 and the second plurality of tabs 260 without trimming the first plurality of tabs 255 or the second plurality of tabs 260.

[0036] Figure 2A The configurations 200 and 250 shown in FIG. 2 show a set of tabs, such as cathode tabs, from a battery stack 210 , 220 . Figure 2B is another diagram illustrating battery cell stacks with different tab lengths according to an embodiment of the present disclosure. In this example, configurations 270 and 280 illustrate examples of battery cell stacks 210 and 220 having both cathode tabs and anode tabs.

[0037] exist Figure 2B , a known configuration 270 shows a battery stack 210 having a cathode tab 212 and an anode tab 214. The battery stack 220 has a cathode tab 222 and an anode tab 224. In this example of a known battery stack configuration, the cathode tabs 212, 222 and the anode tabs 214, 224 have substantially the same length. This results in a portion of the cathode tab overhanging the first (cathode) welding plate 230 at section 215 and a portion of the anode tab overhanging the second (anode) welding plate 235 at section 217 when the respective tabs are folded over to be welded to the plates 230, 235. These extensions must be trimmed, which creates the above-mentioned efficiency and damage risks.

[0038] In contrast, in configuration 280, the first battery stack 210 has cathode tabs 255 and anode tabs 257, while the second battery stack 220 has cathode tabs 260 and anode tabs 262. Tabs 255 are longer than tabs 260, and tabs 257 are longer than tabs 262. The first (cathode) welding plate 230 is welded to the first plurality of cathode tabs 255 and the second plurality of cathode tabs 260 without trimming the first plurality of cathode tabs 255 or the second plurality of cathode tabs 260. Likewise, the second (anode) welding plate 235 is welded to the first plurality of anode tabs 257 and the second plurality of anode tabs 262 without trimming the first plurality of anode tabs 257 or the second plurality of anode tabs 262.

[0039] The cathode tabs 255, 260 can be any suitable length relative to each other. For example, in some embodiments, the cathode tab 260 can be between about 30% and 50% of the length of the cathode tab 255. The cathode tabs 255, 260 can be formed of any suitable material or combination of materials. For example, in some embodiments, the cathode tabs 255, 260 can be formed of aluminum foil comprising at least 99.95% pure aluminum. Similarly, the cathode welding plate 230 is preferably formed of aluminum, such as AL 3003H14 or AL1060H14.

[0040] The anode tabs 257, 262 can also have any suitable length relative to each other, and the anode tab 257 does not necessarily need to be the same length as the cathode tab 255, nor does the anode tab 262 necessarily have the same length as the cathode tab 260. In some embodiments, the anode tab 262 is between about 30% and 50% of the length of the anode tab 257. The anode tabs 257, 262 can be formed of any suitable material or combination of materials. For example, in some embodiments, the anode tabs 257, 262 are formed of copper foil including at least 99.95% pure copper. Similarly, the anode welding plate 235 is preferably formed of copper, such as CU T2.

[0041] Figure 3 is a diagram showing an example of different battery tab lengths according to an embodiment of the present disclosure. In this example, the first electrode and the second electrode are shown as being Figure 2A and Figure 2B The tab lengths used in conjunction with the first battery stack 210 and the second battery stack 220 (respectively) shown in FIG. Figure 3 In the embodiment, the first electrode has a coated area 300 and a tab 310 extending from the coated area 300. The tab 310 has a length 315, which can vary based on factors such as the size of the battery module and its application. Figure 1 In a battery module used in a vehicle 100 in FIG. 1 , the tab 310 may have a length 315 between about 10 mm and 30 mm. The second electrode has a coated region 320 and a tab 330 extending from the coated region 320. As with the tab 310, the length of the tab 330 may vary according to various considerations. In this example, the tab 330 has a length 335 between about 30% and 50% of the length 315 of the tab 310.

[0042] The term "one" does not indicate a limitation of quantity, but indicates the presence of at least one of the referenced items. Unless the context clearly indicates otherwise, the term "or" means "and / or". References to "aspects" throughout the specification mean that a particular element (e.g., a feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0043] 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 intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements present.

[0044] Unless otherwise indicated herein, all test standards are the most current standards in effect as of the filing date of this application or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.

[0045] Unless defined otherwise, 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 belongs.

[0046] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from its scope. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the disclosure without departing from the basic scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A battery cell, comprising: a first battery stack comprising a first plurality of tabs extending from the first battery stack; a second battery stack adjacent to the first battery stack, wherein the second battery stack includes a second plurality of tabs extending from the second battery stack, wherein the second plurality of tabs are shorter than the first plurality of tabs; as well as A welding plate is welded to the first plurality of tabs and the second plurality of tabs without trimming the first plurality of tabs.

2. The battery cell according to claim 1, wherein: The first plurality of tabs is a first plurality of cathode tabs, the second plurality of tabs is a second plurality of cathode tabs, and the welding plate is a first welding plate, the battery cell further comprising: a first plurality of anode tabs extending from the first cell stack; a second plurality of anode tabs extending from the second cell stack, wherein the second plurality of anode tabs are shorter than the first plurality of anode tabs; and A second welding plate is welded to the first plurality of anode tabs and the second plurality of anode tabs without trimming the first plurality of anode tabs.

3. The battery cell according to claim 2, wherein: The first plurality of cathode tabs extend from a first end of the first battery stack, the second plurality of cathode tabs extend from a first end of the second battery stack, the first plurality of anode tabs extend from a second end of the first battery stack, the second plurality of anode tabs extend from a first end of the second battery stack, the first end of the first battery stack is opposite to the second end of the first battery stack, and the first end of the second battery stack is opposite to the second end of the second battery stack.

4. The battery cell according to claim 2, wherein: The first plurality of cathode tabs and the second plurality of cathode tabs include aluminum.

5. The battery cell according to claim 2, wherein: The first plurality of anode tabs and the second plurality of anode tabs include copper. The battery cell according to claim 2 , wherein the first welding plate comprises aluminum, and the second welding plate comprises copper.

7. The battery cell according to claim 1, wherein: The first plurality of tabs have a length between about 10 mm and 30 mm, and wherein the second plurality of tabs are between about 30%-50% of the length of the first plurality of tabs.

8. A system comprising: A battery cell, the battery cell comprising: a first battery stack comprising a first plurality of tabs extending from the first battery stack; a second battery stack adjacent to the first battery stack, wherein the second battery stack includes a second plurality of tabs extending from the second battery stack, wherein the second plurality of tabs are shorter than the first plurality of tabs; and A welding plate is welded to the first plurality of tabs and the second plurality of tabs without trimming the first plurality of tabs.

9. The system according to claim 8, wherein: The first plurality of tabs is a first plurality of cathode tabs, the second plurality of tabs is a second plurality of cathode tabs, and the welding plate is a first welding plate, the battery cell further comprising: a first plurality of anode tabs extending from the first cell stack; a second plurality of anode tabs extending from the second cell stack, wherein the second plurality of anode tabs are shorter than the first plurality of anode tabs; and A second welding plate is welded to the first plurality of anode tabs and the second plurality of anode tabs without trimming the first plurality of anode tabs.

10. A vehicle comprising: Electric motor; as well as a battery unit coupled to the electric motor, the battery unit comprising: a first battery stack comprising a first plurality of tabs extending from the first battery stack; a second battery stack adjacent to the first battery stack, wherein the second battery stack includes a second plurality of tabs extending from the second battery stack, wherein the second plurality of tabs are shorter than the first plurality of tabs; and A welding plate is welded to the first plurality of tabs and the second plurality of tabs without trimming the first plurality of tabs.

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