Welded plate for battery cell current collector

Abstract

A system for electrically connecting tabs of a battery cell includes an electrically conductive welded plate configured to be disposed within a housing of the battery cell and electrically connected to a tab stack formed of a plurality of tabs extending from an electrode layer of the stack. The welding plate has a first welding surface and a deformable portion defining a second welding surface, and the deformable portion is configured to deform and remain in a deformed state during welding of the tab stack to the welding plate.

Description

Technical Field

[0001] The presently disclosed subject matter relates to batteries, and more particularly, to the manufacture and assembly of battery cells. Background Art

[0002] Battery cells are used in various applications, such as automotive applications (e.g., electric vehicles and hybrid vehicles). For example, battery systems for electric and hybrid vehicles include battery modules having multiple battery cells. Battery cells can be prismatic or other types of batteries and typically include multiple layers of anode material and cathode material. The anode layers are electrically connected by welding a stack of anode tabs, and the cathode layers are electrically connected by welding a stack of cathode tabs. Summary of the Invention

[0003] In one exemplary embodiment, a system for electrically connecting tabs of a battery cell includes a conductive welding plate configured to be disposed within a battery cell housing and electrically connected to a tab stack formed by a plurality of tabs extending from electrode layers of a battery stack. The welding plate has a first welding surface and a deformable portion defining a second welding surface, and the deformable portion is configured to deform and remain in the deformed state during welding of the tab stack to the welding plate.

[0004] In addition to one or more features described herein, the system also includes a welding device configured to weld the tab stack to the first welding surface and the second welding surface to form at least a portion of the connector.

[0005] In addition to one or more features described herein, the first weld surface is defined by the first arm, the second weld surface faces the first weld surface and is defined by the second arm, and the second arm is configured to be deformed by moving the second arm toward the first arm.

[0006] In addition to one or more features described herein, the welding plate includes a clip attached to the inner surface of the cover plate assembly, the clip having a first member attached to the inner surface and a movable member connected to the first member.

[0007] In addition to one or more features described herein, the clip has an open state configured to allow the tab stack to be inserted into the clip and a closed state in which the movable member is positioned relative to the first member such that the first and second welding surfaces contact the tab stack.

[0008] In addition to one or more features described herein, the movable member is connected to the first member at a pivot point.

[0009] In addition to one or more features described herein, the clip has an open state configured to allow a tab stack to be inserted into the clip and a closed state achieved by folding the clip by rotating the movable member about a pivot point.

[0010] In addition to one or more features described herein, the first weld surface and the second weld surface are planar surfaces and are configured to maintain the tab stack in a planar configuration and undeformed state during welding.

[0011] In another exemplary embodiment, a method for electrically connecting tabs of a battery cell includes obtaining a battery stack configured to be disposed within a housing to form a battery cell, wherein a plurality of tabs extend from an electrode layer of the battery stack, forming a tab stack from portions of the plurality of tabs, and positioning the tab stack against a first welding surface of a welding plate having a deformable portion defining a second welding surface. The method also includes deforming the deformable portion to bring the second welding surface into contact with the tab stack, and welding the tab stack to the first welding surface and the second welding surface using a welding device to form at least a portion of a connector, wherein the tab stack is welded while the deformable portion remains in the deformed state.

[0012] In addition to one or more features described herein, the tab stack is welded while maintaining the tab stack in a planar configuration and an undeformed state, wherein the undeformed state is a state in which the tab stack is not folded prior to welding and is not subjected to bending forces during welding.

[0013] In addition to one or more features described herein, the first weld surface is defined by the first arm, and the second weld surface faces the first weld surface and is defined by the second arm.

[0014] In addition to one or more features described herein, providing the tab stack includes inserting the tab stack into a slot defined by the first arm and the second arm, and deforming the second arm to move the second welding surface toward the first arm and into contact with the tab stack.

[0015] In addition to one or more features described herein, the welding plate includes a clip attached to the inner surface of the cover plate assembly, the clip having a first member attached to the inner surface and a movable member connected to the first member.

[0016] In addition to one or more features described herein, providing the tab stack includes inserting the tab stack into the clamp when the clamp is in an open state, and moving the movable member toward the first member such that the first and second weld surfaces contact the tab stack.

[0017] In addition to one or more features described herein, the movable member is connected to the first member at a pivot point, and positioning the tab stack includes inserting the tab stack into the clamp when the clamp is in an open state and collapsing the clamp by rotating the movable member about the pivot point.

[0018] In another exemplary embodiment, a computer program product includes a computer-readable memory having computer-executable instructions stored thereon, the computer-executable instructions causing the processor to perform operations when executed by a processor. The operations include obtaining a battery stack configured to be disposed within a housing to form a battery cell, wherein a plurality of tabs extend from an electrode layer of the battery stack. The operations also include forming a tab stack from a portion of the plurality of tabs, positioning the tab stack against a first welding surface of a welding plate having a deformable portion defining a second welding surface, deforming the deformable portion to bring the second welding surface into contact with the tab stack, and welding the tab stack to the first welding surface and the second welding surface using a welding device to form at least a portion of the connector, wherein the tab stack is welded while the deformable portion remains in the deformed state.

[0019] In addition to one or more features described herein, the first weld surface is defined by the first arm, and the second weld surface faces the first weld surface and is defined by the second arm.

[0020] In addition to one or more features described herein, providing the tab stack includes inserting the tab stack into a slot defined by the first arm and the second arm, and deforming the second arm to move the second welding surface toward the first arm and into contact with the tab stack.

[0021] In addition to one or more features described herein, the welding plate includes a clip attached to the inner surface of the cover plate assembly, the clip having a first member attached to the inner surface and a movable member connected to the first member.

[0022] In addition to one or more features described herein, providing the tab stack includes inserting the tab stack into the clamp when the clamp is in an open state, and moving the movable member toward the first member such that the first and second weld surfaces contact the tab stack.

[0023] The above features and advantages and other features and advantages of the present disclosure will become apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Additional features, advantages, and details appear, by way of example only, in the following detailed description, which refers to the accompanying drawings, in which:

[0025] Figure 1 depicts a battery cell according to an exemplary embodiment;

[0026] Figure 2 depicts a battery cell according to an exemplary embodiment;

[0027] Figure 3 depicts a system for manufacturing battery cells according to an exemplary embodiment;

[0028] Figure 4 depicts a welding plate for electrically connecting components of a battery cell according to an exemplary embodiment;

[0029] Figure 5 Depicted is a diagram including a Figure 4 The lug connection assembly of the welding plate;

[0030] Figure 6 Depicts the welding process used to connect a battery cell to a tab connection assembly. Figure 5 Tab connection components;

[0031] Figure 7 Depicts the welding process used to connect a battery cell to a tab connection assembly. Figure 6 Tab connection components;

[0032] Figure 8 Depicted is a tab connection assembly according to an exemplary embodiment, the tab connection assembly including a welding plate having a clip for connecting a battery cell to the tab connection assembly;

[0033] Figure 9 Depicts Figure 8 Tab connection components and welding plates;

[0034] Figures 10A-10D Depicted is a diagram according to an exemplary embodiment Figure 8 Aspects of a clip and a method of electrically connecting a battery cell tab and manufacturing a battery cell;

[0035] Figure 11 depicts a tab connection assembly including a welding plate having clips for connecting a battery cell to the tab connection assembly according to an exemplary embodiment; and

[0036] Figure 12 Depicts Figure 8 The tab connection components and welding plates. DETAILED DESCRIPTION

[0037] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0038] According to one or more exemplary embodiments, the present disclosure provides methods, devices, and systems for facilitating the attachment and electrical connection of electrodes (anodes and cathodes) in battery cells. Embodiments of the system for consolidating and joining portions of electrodes or electrode layers include a connection assembly configured to perform functions associated with forming a battery tab stack, welding the tab stack, and forming a connector for the battery cell.

[0039] One embodiment of a connection assembly includes an internal terminal welding plate (also referred to as an internal welding plate) configured to be attached to and electrically connected to one or more tab stacks. The welding plate includes at least one deformable portion such that the portion can deform and remain in the deformed state during welding.

[0040] In one embodiment, the welding plate defines a pair of welding surfaces for welding the tab stack to the welding plate. The pair of welding surfaces are combined together during welding to contact the tab stack (and optionally compress the tab stack). The welding surface can be configured as a planar surface, or otherwise configured so that the tab stack is in a planar form. When the tab stack (or at least a portion of the tab stack subjected to welding) is oriented vertically, horizontally, or otherwise linearly, the tab stack is in a "planar form". Therefore, the tab stack can be welded or joined without folding any portion of the tab stack (e.g., any portion subjected to welding) and without being deformed by bending forces.

[0041] The internal welding plate can have any of a variety of configurations. For example, the welding plate includes one or more welding portions, each of which includes opposing arms defining opposing surfaces. After the tab stack is inserted into the portion, at least one arm is deformed (e.g., by a clamp) so that the opposing surface contacts the tab stack. In another example, the welding plate includes one or more clips that can be opened (or in an initial open position) to insert the tab stack and can be closed to contact the tab stack for subsequent compression and / or welding by the tab stack and the clip.

[0042] The embodiments described herein present many advantages and technical effects. These embodiments provide an improved manufacturing process that is conducive to the correct attachment and electrical connection of electrode tabs. For example, an embodiment provides an advanced junction box that enhances the durability of the terminal after the welding process. Without the need for pre-welding (e.g., ultrasonic welding), these embodiments allow welding or joining tab stacks and constructing terminals.

[0043] Embodiments of the advanced junction box utilize a U-shaped design that minimizes empty space to the extent necessary for the thickness of the battery tab. These embodiments also enable the use of a butterfly welding method in prismatic can batteries. By implementing this welding technique, the embodiments enhance the robustness of the welded connection between the tab and the junction box.

[0044] Figure 1 and Figure 2 An example of a battery cell 10 is depicted. The battery cell includes a housing 12, which can be a rigid housing designed for prismatic cells. For example, the housing is a rectangular housing or "can" made of aluminum or other materials. The embodiments described herein are not limited to any particular type of battery cell, or electrodes and housings of any particular shape, size, or material. For example, the embodiments can be adapted for batteries having various types of housings.

[0045] The battery cell 10 includes multiple layers that form a negative electrode, or anode, and a positive electrode, or cathode. The anode is made of a conductive anode layer 14, and the cathode is made of a conductive cathode layer 16. The anode layer 14 and the cathode layer 16 are constructed as thin sheets or foils. A separator 18 made of an electrically insulating material (such as a polymer or ceramic) is disposed between each anode layer 14 and the adjacent cathode layer 16. Active material 20 (such as graphite or a material containing lithium) is disposed between the layers within the housing 12. These internal layers form a battery cell stack 22.

[0046] It should be noted that the number of electrodes is not limited to Figure 1 The battery cell 10 may have any number of anode layers 14 and any number of cathode layers 16. For example, the battery cell 10 may have hundreds of individual foil layers forming the electrode layers.

[0047] like Figure 1 As shown, each anode layer 14 includes a portion 24 that extends away from the interior of the battery 10 and allows each anode layer 14 to be electrically connected to another anode layer 14. This portion 24 is also referred to as a tab 24 or a connecting tab 24. Although not shown, the cathode layer 16 includes a tab so that the cathode layer 16 can be connected. The cathode layer tab (not shown) can extend from the opposite end (in the z-direction) as the anode tab 24 or from the same end.

[0048] The portions (or subsets thereof) of the tabs 24 are stacked together as at least one tab stack 26. The portions comprising each tab stack 26 are welded together, for example, by laser welding. The battery 10 is not limited thereto, as other techniques, such as ultrasonic and other metal-to-metal joining processes, may be used. In one embodiment, laser welding is used to weld the tab stacks (which can be effectively achieved without ultrasonic pre-welding).

[0049] Each tab stack 26 is welded to a conductive member 28 ("welding plate") that provides a contact point for welding the tab stacks 26 together and can serve as at least a portion of a connector. The connector forms the negative terminal. The cathode layer 16 can be similarly welded to a positive terminal (not shown) that extends to the exterior of the housing 12. The welding plate 28 can form a connector alone or in combination with other electrical conductors.

[0050] In one embodiment, the welding plate 28 includes at least one welding portion 30. The welding portion 30 defines a pair of surfaces ("welding surfaces") that provide welding contact points at which the tab stack 26 is fused to the welding plate 28.

[0051] For example, the weld portion 30 includes a first weld surface 32 and a second weld surface 34. The portion 36 of the weld plate including the second weld surface 34 is deformable so that the second weld surface 34 can be moved generally toward the first weld surface 32. In this way, during the welding process, the surfaces 32 and 34 can be brought together to contact the tab stack 26 to ensure proper contact and fusion of the tab stack 26 with the surfaces 32 and 34. Note that the deformable portion 36 can be an integral part of the weld plate 28 (i.e., as a single piece) or attached to the remainder of the weld plate 28.

[0052] In one embodiment, surfaces 32 and 34 are configured to provide a base that allows the tab stack 26 to be welded without folding, deflecting, or otherwise applying bending forces (as opposed to tension forces that may be applied during welding) to the portions that make up the tab stack (i.e., the portions that are fused to each other and to the weld plate 28). In one embodiment, each welding surface 32 and 34 is a generally planar surface.

[0053] Figure 1 An example is shown in which tabs 24 are gathered and joined into a single tab stack 26 for the anode layer 14 (a single tab stack for connecting cathode layers can be similarly formed).

[0054] Figure 2 An example is shown in which the tabs 24 are grouped into two separate tab stacks 26 (designated as tab stacks 26a and 26b), each of which is welded to a corresponding weld portion 30 (designated as portions 30a and 30b). Weld portion 30a includes opposing weld surfaces 32a and 34a, and weld portion 30b includes opposing weld surfaces 32b and 34b.

[0055] Figure 3An example of a manufacturing system 40 for manufacturing battery cells is depicted. Manufacturing system 40 includes various manufacturing stations that can be controlled or operated by a computer system, an operator, or a combination thereof. As used herein, "station" refers to any number, combination, and arrangement of equipment and is not intended to limit manufacturing system 40 to any particular machine or combination of machines.

[0056] The manufacturing system 40 includes, for example, an active material processing station 42 for preparing active materials to be applied to electrode layers. The system 40 may also include a coating station 44 for coating electrodes with active materials. The manufacturing system 40 also includes an electrode cutting station 46 that can be used to form electrode layers and tabs from sheets of electrode material (e.g., copper and aluminum sheets).

[0057] The system 40 also includes a stacking station 48 for forming the various layers of the battery stack and a welding station 50 for welding the electrode layer tabs. In conjunction with the welding equipment, the welding station 50 may include the welding plate 28 described herein.

[0058] The system 40 may include or be connected to one or more processing devices for performing various aspects of manufacturing. For example, the welding station 50 is connected to a controller 52 for controlling processes such as bonding, trimming, and / or welding.

[0059] The system 40 may include other stations for performing subsequent processes to complete the battery cells. Examples include assembly stations (e.g., for battery pack or housing construction, sealing, electrolyte filling, etc.), and stations for manufacturing battery components (e.g., battery packs and / or modules).

[0060] For example, the battery cells may be mounted in a battery assembly. A battery assembly may be a battery module having a plurality of electrically connected battery cells, such as a battery module incorporated into a vehicle (eg, an electric or hybrid vehicle) as part of a battery pack.

[0061] Figure 4 is a perspective view of an embodiment of a weld plate 28 shown in an x, y, z coordinate system. Figure 5 is a cross-sectional view (along the yz plane) of the tab connection assembly 60 including the welding plate. Although the welding plate 28 is shown as having two welding portions, embodiments are not limited thereto as the welding plate 28 may have a single welding portion.

[0062] like Figure 4 As shown, the welding plate 28 is integrally formed into opposing welding portions 30a and 30b. Each welding portion 30a and 30b has a deformable portion 36 in the form of an arm or connecting member that is movable toward the opposing arm or member.

[0063] Figure 5An embodiment of a tab connection assembly 60 is depicted that includes a welding plate 28. In this embodiment, the welding plate 28 is configured to be disposed within a housing (e.g., Figure 1 and Figure 2 The internal terminal welding plate 28 in the prismatic housing 12) of the tab connection assembly 60 includes a connector formed of a conductive material (and configured to provide an electrical connection between the anode layer and the device to be powered).

[0064] For example, the tab connection assembly 60 includes a cover plate 62 that is fixedly disposed relative to the welding plate 28. The cover plate 62 can form part of the cover of the battery assembly and can be attached directly to the welding plate 28 or attached to the welding plate 28 via an isolation insert 64. Other components (e.g., feedthroughs, terminals, etc.) can also be coupled to the welding plate 28 to form the connection assembly 60. All components of the connection assembly 60 can move as a single unit.

[0065] Each welding portion 30a, 30b includes a pair of arms defining opposing welding surfaces. At least one arm is deformable so that the arms can be deformed to bring the welding surfaces closer together and contact the tab stack inserted therein. In addition, the arms can be joined together to compress the tab stack.

[0066] For example, Figure 4 and Figure 5 As shown, weld portion 30a includes a first surface 32a defined by first arm 66a and a second surface 34a defined by second arm 68a. Weld portion 30b includes a first surface 32b defined by first arm 66b and a second surface 34b defined by second arm 68b. One or more arms (or all arms) may have rounded edges or be otherwise configured so that there are no sharp edges that could cause tearing.

[0067] Various methods for forming anode tabs and welding one or more anode tab stacks to an anode welding plate are described herein. It should be understood that these methods are also applicable to cathode tabs.

[0068] Figure 6 and Figure 7 Shows the use of Figure 5 Various aspects of a method for manufacturing a battery cell with a tab connection assembly 60 are described. The method (or portions thereof) may be performed by any suitable one or more processing devices, such as one or more controllers of the manufacturing system 40 (e.g., controller 52 connected to the welding station 50), but is not limited thereto.

[0069] The method includes a plurality of steps or phases. The method is not limited to the number or order of the steps therein, as some steps may be performed in a different order than described below, or fewer than all steps may be performed.

[0070] In the first stage, an electrode is manufactured or obtained, which includes an anode sheet and a cathode sheet made of a coated conductive material, for example, the anode sheet is made of copper and the cathode sheet is made of aluminum.

[0071] The anode and cathode sheets are coated, cut, trimmed, and / or otherwise processed to produce anode and cathode layers, and the anode and cathode layers are assembled with other layers (e.g., separator layers) to form the cell stack 22. Each anode and cathode layer has a corresponding tab extending from the cell stack.

[0072] The anode tab 24 is divided into two tab groups 24a and 24b (see Figure 2 ), thereby forming tab stacks 26a and 26b. Additionally, the cell stack is divided into two cell stack portions 22a and 22b, allowing the use of a so-called butterfly approach, which will be discussed further herein.

[0073] like Figure 6 As shown, tab 26a is inserted into the slot formed by arms 66a and 68a, and tab stack 24b is inserted into the slot formed by arms 66b and 68b. Optionally, a clamp or other device can be used to apply force to arms 68a and 68b to combine tab stacks 26a and 26b and facilitate forming a weld. In the butterfly method, cell stacks 22a and 22b are placed on opposite sides of welding plate 28.

[0074] The laser welding device 67 (or other welding device) is used to apply one or more laser beams 69 to fuse the tab group (tab stack) to the welding plate 28. For example, the laser welding device 67 is used to simultaneously fuse the tab stack 26a to both the first arm 66a and the second arm 68, and to fuse the tab stack 26b to the first arm 66b and the second arm 68b.

[0075] like Figure 7 As shown, after welding is completed, the battery stack portions 22a and 22b can be joined together or otherwise configured for packaging within a housing. For example, the tab stacks 26a and 26b are folded approximately 90 degrees, and the battery stack portions 22a and 22b are rotated, joined together, and adhered or otherwise attached to form the consolidated battery stack 22.

[0076] Additional steps or stages may be performed to complete assembly of the battery cell 10 (eg, mounting the welded electrodes in a housing (eg, a pouch or rigid housing) with a separator layer), quality inspection, electrolyte filling, housing sealing, etc.

[0077] In one embodiment, the welding plate 28 includes one or more separate structures (referred to herein as "clips") that define slots or receptacles for the tab stacks. Figure 8 、 Figure 9and 10A - Figure 10D An embodiment of a welding plate 28 is depicted that includes at least one clip 70 (at Figure 8 and Figure 9 70a and 70b). The clips may be integrally formed with the connection assembly 60 or welded or otherwise attached to a component of the connection assembly 60. Additionally, the clips 70 may be a single clip or a plurality of clips.

[0078] See also Figure 8 and Figure 9 , the clip 70 includes a first clip 70a having a first member 72a attached to or integral with the connecting assembly 60. The clip 70a also includes a second member 74a connected to the first member 72a such that the second member 74a is movable relative to the first member 72a. For example, the second member 74a is connected to the first member 72a via a pivot point 76a, which allows the clip 70a to be opened and closed by rotating the second member 74a.

[0079] Likewise, the welding plate 28 includes a second clamp 70b having a first member 72b attached to or integral with the cover assembly 60 and a second member 74b movable relative to the first member 72b via a pivot point 76b. The clamp 70b can be opened and closed by rotating the second member 74b about the pivot point 76b.

[0080] The pivot points (ie, pivot points 76a and / or 76b) may take any suitable form. For example, a relatively thin or flexible portion may form the pivot point, or a pin, hinge or other mechanism may be provided to allow rotation.

[0081] Figure 8 The clips 70a and 70b are shown in a closed state, wherein each clip 70a and 70b defines a corresponding slot for inserting the tab stack. In this state, the arms of each clip 70a and 70b can be compressed by the clamp 78 to ensure good contact and / or bonding. After welding (e.g., using the laser beam 69), the battery stack portions 22a and 22b are rotated and joined together, as shown. Figure 9 shown.

[0082] Figures 10A-10D Aspects of a method of manufacturing a battery cell are shown. The method (or portions thereof) may be performed by any suitable one or more processing devices, such as, but not limited to, one or more controllers (e.g., controller 52) of manufacturing system 40 and / or connection system 60.

[0083] The method includes a plurality of steps or phases. The method is not limited to the number or order of the steps therein, as some steps may be performed in a different order than described below, or fewer than all steps may be performed.

[0084] In the first stage, electrodes are manufactured or obtained and processed to form the battery stack 22 connected to the anode tabs 24 and the cathode tabs. The anode tabs can be divided into two tab groups (eg, tab stacks 24a and 24b).

[0085] In the second stage, see Figure 10A , the anode tabs 24 are assembled into the tab stack 26 and inserted into the clip 70 (eg, one of the clips 70a, 70b). As shown, the clip 70 is in an open state, wherein the first member 72 and the second member 74 define a relatively wide opening.

[0086] The clip 70 may be configured so that the clip 70 is in an open state by default. Alternatively, the clip 70 may be in a closed state by default and opened to place the clip 70 in an open state.

[0087] The third stage, see Figure 10B , the clamp 70 is closed by moving the second member 74 closer to the first member 72. A clamp 78 may be applied to compress the tab stack 26 and ensure good contact.

[0088] The fourth stage, see Figure 10C As the clamp 78 applies pressure, the laser beam 69 is applied to the clip 70 and the tab stack 26. The laser beam 69 forms a weld through the tab stack 26 and portions of the first and second members 72, 74, fusing the tab stack 26 to the clip 70.

[0089] The fifth stage, see Figure 10D , using a butterfly method to rotate the stack 22. Additional steps or stages may be performed to complete the assembly of the battery cell 10 (e.g., mounting the welded electrodes in a housing (e.g., a pouch or rigid housing) with a separator layer), quality inspection, electrolyte filling, housing sealing, etc.

[0090] Figure 11 and Figure 12 An embodiment of the connection assembly 60 is depicted in which the clips 70 (clips 70a and 70b) are generally L-shaped clips. For example, Figure 11 As shown, the clip 70a includes a first member 72a and a second member 74a in an open position. Similarly, the clip 70b includes a first member 72b and a second member 74b in an open position.

[0091] In the open position, the second member 74a is perpendicular to (or at least partially perpendicular to) the first member 72a. Note that in the open position, the second member 74a may not be perpendicular (eg, forming an angle less than 90 degrees, such as 45 degrees or 60 degrees).

[0092] Figure 11 The clips 70a and 70b are shown in an open position. The tab sets 26a and 26b are also shown inserted into the clips 70a and 70b.

[0093] like Figure 12 As shown, after the tab group is inserted, the clamp closes to form a U-shape that encloses the corresponding tab stack 26a and 26b. Subsequently, the clamp and tab stack are compressed using a clamping device 78 and welded using a laser 69 to fuse the tab to the clamp.

[0094] The terms "a" and "an" do not indicate a quantitative limitation, but rather indicate the presence of at least one of the referenced items. The term "or" means "and / or" unless the context clearly indicates otherwise. References throughout this specification to "an aspect" mean that a particular element (e.g., 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.

[0095] 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.

[0096] Unless otherwise specified herein, all test standards are the most current standards in effect as of the filing date of this application or, if priority is claimed, as of the filing date of the earliest priority application in which such test standard appears.

[0097] 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.

[0098] Although the above disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope thereof. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, the present disclosure is not intended to be limited to the particular embodiments disclosed, but is intended to include all embodiments falling within its scope.

Claims

1. A system for electrically connecting tabs of a battery cell, comprising: A conductive welding plate configured to be disposed within the housing of the battery cell and electrically connected to a tab stack formed by a plurality of tabs extending from an electrode layer of the battery stack, the welding plate having a first welding surface and a deformable portion defining a second welding surface, wherein the deformable portion is configured to deform and remain in a deformed state during welding of the tab stack to the welding plate. 2 . The system of claim 1 , further comprising a welding device configured to weld the tab stack to the first welding surface and the second welding surface to form at least a portion of a connector.

3. The system according to claim 1, wherein: The first welding surface is defined by a first arm, and the second welding surface faces the first welding surface and is defined by a second arm, and the second arm is configured to be deformed by moving the second arm toward the first arm.

4. The system according to claim 1, wherein: The welding plate includes a clip attached to an inner surface of a cover plate assembly, the clip having a first member attached to the inner surface and a movable member connected to the first member.

5. The system according to claim 4, wherein: The clip has an open state configured to allow a tab stack to be inserted into the clip and a closed state in which the movable member is positioned relative to the first member such that the first and second welding surfaces contact the tab stack.

6. The system according to claim 4, wherein: The movable member is connected to the first member at a pivot point.

7. The system according to claim 6, wherein: The clip has an open state configured to allow a tab stack to be inserted into the clip, and a closed state achieved by folding the clip, wherein the folding of the clip is achieved by rotating the movable member about the pivot point.

8. The system according to claim 1, wherein: The first welding surface and the second welding surface are planar surfaces and are configured to maintain the tab stack in a planar configuration and in an undeformed state during welding.

9. A method for electrically connecting tabs of a battery cell, comprising: Obtaining a battery stack configured to be disposed within a housing to form the battery cell, wherein a plurality of tabs extend from an electrode layer of the battery stack; forming a tab stack from a portion of the plurality of tabs and positioning the tab stack against a first weld surface of a weld plate having a deformable portion defining a second weld surface; and The deformable portion is deformed so that the second welding surface contacts the tab stack, and the tab stack is welded to the first welding surface and the second welding surface by a welding device to form at least a portion of a connector, wherein the tab stack is welded while the deformable portion remains in a deformed state.

10. The method according to claim 9, wherein: The first welding surface is defined by a first arm, and the second welding surface faces the first welding surface and is defined by a second arm, and wherein setting the tab stack includes inserting the tab stack into a narrow slot defined by the first arm and the second arm, and deforming the second arm to move the second welding surface toward the first arm and into contact with the tab stack.

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