Direct foil-to-terminal connection design for prismatic cell fabrication

Abstract

A method for manufacturing a prismatic battery assembly includes disposing a plurality of current collector tabs at least partially through a slot of a cap of a housing. A plurality of current collector tabs are electrically connected to respective current collectors of the electrode stack and extend from an end of the electrode stack. The housing accommodates the electrode stack. The cap has an inner side extending along an end of the electrode stack and an outer side opposite the inner side. A slot is formed through the cap between the outer side and the inner side. Where the plurality of current collector tabs are disposed at least partially through the slot, the method includes electrically connecting the plurality of current collector tabs to a terminal plate disposed at an outer side of the cap and hermetically sealing the housing.

Description

[0001] introduction

[0002] The information provided in this section is for the purpose of presenting the general context of this disclosure. The work of the currently attributed inventors, to the extent described in this section, and aspects of the description that might not otherwise be considered prior art at the time of filing, are neither expressly nor implicitly acknowledged as prior art to this disclosure. Technical Field

[0003] This disclosure generally relates to a prismatic battery having an electrode stack electrically connected to a terminal plate at a battery cap. Background Technology

[0004] Typically, the electrode stack of a prismatic battery is electrically connected to the terminal plate of the battery cap via a current collector of the electrode stack welded to internal terminal leads at the battery cap. That is, the battery cap includes internal terminal leads located inside the battery cap, which are electrically connected to a terminal plate located outside the battery cap. To provide access to the terminal plate and current collector during battery manufacturing, the current collector is welded to the terminal leads, with the electrode stacks spread apart relative to each other or oriented substantially horizontally relative to the battery cap. After welding, the electrode stacks are then moved together and oriented substantially vertically relative to the battery cap for placement within the battery assembly. Moving the electrode stacks to a vertical orientation after welding the current collector to the terminal leads causes the current collector to fold or bend relative to the terminal leads, which can lead to increased stress on the current collector. Under certain conditions, such as when a vehicle equipped with a prismatic battery is in motion, the current collector may tear or break off from the terminal leads due to the relative movement between the current collector and the terminal leads. Furthermore, because the connection between the current collector and the terminal leads is located inside the battery cap, the battery assembly must provide sufficient clearance between the inside of the battery cap and the electrode stack, resulting in an increase in the battery assembly's encapsulation. Summary of the Invention

[0005] One aspect of this disclosure provides a method for manufacturing a prismatic battery assembly. The method includes arranging a plurality of current collector tabs at least partially through a slot in a cap of an enclosure. The plurality of current collector tabs are electrically connected to respective current collectors of an electrode stack and extend from an end of the electrode stack. The enclosure houses the electrode stack. The cap has an inner side extending along an end of the electrode stack and an outer side opposite to the inner side. The slot is formed through the cap between the outer and inner sides. With the plurality of current collector tabs arranged at least partially through the slot, the method includes electrically connecting the plurality of current collector tabs to a terminal plate disposed on the outer side of the cap. With the plurality of current collector tabs electrically connected to the terminal plate, the method includes hermetically sealing the enclosure.

[0006] Embodiments of this disclosure may include one or more of the following optional features. In some embodiments, arranging a plurality of current collector tabs to at least partially pass through a slot includes collecting the plurality of current collector tabs and moving a cap relative to the end of the electrode stack to feed the plurality of current collector tabs at least partially through the slot. A cover hermetically seals the housing.

[0007] In some examples, where multiple current collector tabs are configured to at least partially pass through a slot, the multiple current collector tabs extend through the slot of the cap and at least partially extend along the terminal plate outside the cap. The multiple current collector tabs are disposed between the terminal plate and the cover plate. In another example, where the multiple current collector tabs extend at least partially along the terminal plate, the multiple current collector tabs are received within a recess formed between the terminal plate and the cover plate. The recess may extend partially into one of the terminal plate and the cover plate.

[0008] In some aspects, where multiple current collector tabs are configured to at least partially pass through a slot, the multiple current collector tabs extend through the slot of the cap, and the multiple current collector tabs extend at least partially through the slot of the terminal plate. In another aspect, electrically connecting the multiple current collector tabs to the terminal plate includes attaching the multiple current collector tabs to the terminal plate at a slot in the terminal plate. In a further aspect, the method also includes attaching a cover plate to the terminal plate. The cover plate extends over the multiple current collector tabs and the slot of the terminal plate and hermetically seals the housing.

[0009] In some implementations, electrically connecting multiple current collector tabs to a terminal block includes attaching multiple current collector tabs to lead tabs. The lead tabs are electrically connected to the terminal block and extend within a slot in the cap.

[0010] In some examples, electrically connecting multiple current collector tabs to a terminal block involves laser welding multiple current collector tabs. Multiple current collector tabs are laser welded to the terminal block.

[0011] Another aspect of this disclosure provides a prismatic battery assembly. The prismatic battery assembly includes an electrode stack having a plurality of current collector tabs electrically connected to respective current collectors of the electrode stack. The plurality of current collector tabs extend from an end of the electrode stack. A housing accommodates the electrode stack. The housing includes a cap. The cap has an inner side extending along an end of the electrode stack and an outer side opposite to the inner side. A slot is formed through the cap between the outer and inner sides. The plurality of current collector tabs extend at least partially through the slot. A terminal plate is disposed on the outer side and electrically connected to the plurality of current collector tabs. This aspect may include one or more of the following optional features.

[0012] In some embodiments, a plurality of current collector tabs extend through a slot in the cap and at least partially along the terminal plate on the outside of the cap. The plurality of current collector tabs are disposed between the terminal plate and the cover plate. In a further embodiment, the plurality of current collector tabs are received within a recess formed between the terminal plate and the cover plate.

[0013] In some examples, multiple current collector tabs extend through the slot of the cap and at least partially through the slot of the terminal block. The multiple current collector tabs are attached to the terminal block at the slot of the terminal block.

[0014] In some aspects, multiple current collector tabs extend partially through the slot and are attached to lead tabs. The lead tabs are electrically connected to the terminal block and extend within the slot of the cap.

[0015] Another aspect of this disclosure provides a vehicle including a prismatic battery assembly. The prismatic battery assembly includes an electrode stack having a plurality of current collector tabs electrically connected to respective current collectors of the electrode stack. The plurality of current collector tabs extend from the ends of the electrode stack. A housing accommodates the electrode stack. The housing includes a cap. The cap has an inner side extending along the ends of the electrode stack and an outer side opposite to the inner side. A slot is formed through the cap between the outer and inner sides. The plurality of current collector tabs extend at least partially through the slot. A terminal plate is disposed on the outer side and electrically connected to the plurality of current collector tabs. This aspect may include one or more of the following optional features.

[0016] In some embodiments, a plurality of current collector tabs extend through a slot in the cap and at least partially along the terminal plate on the outside of the cap. The plurality of current collector tabs are disposed between the terminal plate and the cover plate. In a further embodiment, the plurality of current collector tabs are received within a recess formed between the terminal plate and the cover plate.

[0017] In some examples, multiple current collector tabs extend through the slot of the cap and at least partially through the slot of the terminal block. The multiple current collector tabs are attached to the terminal block at the slot of the terminal block.

[0018] In some aspects, multiple current collector tabs extend partially through the slot and are attached to lead tabs. The lead tabs are electrically connected to the terminal block and extend within the slot of the cap.

[0019] Details of one or more embodiments of this disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the specification, drawings, and claims. Attached Figure Description

[0020] The accompanying drawings described herein are for illustrative purposes only for the selected configurations and are not intended to limit the scope of this disclosure.

[0021] Figure 1 This is a perspective view of a vehicle equipped with prismatic battery packs.

[0022] Figure 2 This is a perspective view of an exemplary prismatic battery assembly.

[0023] Figure 3A and 3B yes Figure 2 A perspective view of the terminal block of the prismatic battery assembly.

[0024] Figure 4 yes Figure 2 A perspective view of an electrode stack of a prismatic battery assembly having current collector tabs attached to the inside of a terminal plate, wherein the electrode stacks are spaced apart from each other and move from the inside of the terminal plate.

[0025] Figures 5A-5C This is a view of another exemplary prismatic battery assembly having a current collector tab extending through a slot formed in the cap of the prismatic battery assembly for attachment to a terminal plate on the outside of the cap.

[0026] Figure 6A and 6B yes Figures 5A-5C A perspective view of the cap of the prismatic battery assembly.

[0027] Figure 7 yes Figures 5A-5C A perspective view of the cap of a prismatic battery assembly, showing the cover plate removed from the terminal plate of the cap.

[0028] Figure 8 Including for Figures 5A-5C Cross-sectional view of an exemplary cover plate and terminal plate of a prismatic battery assembly.

[0029] Figure 9 It is used for manufacturing Figures 5A-5C A schematic diagram of an exemplary method for a prismatic battery assembly.

[0030] Figures 10A-10C This is a view of another exemplary prismatic battery assembly having a current collector tab extending through a slot formed in the cap of the prismatic battery assembly for attachment to a terminal plate at or within the slot.

[0031] Figure 11 It is used for manufacturing Figures 10A-10C A schematic diagram of an exemplary method for a prismatic battery assembly.

[0032] Figures 12A-12C This is a view of another exemplary prismatic battery assembly having a current collector tab extending through a slot formed in the cap of the prismatic battery assembly for attachment to a terminal plate at or within the slot.

[0033] Figure 13 yes Figures 12A-12C A perspective view of the cap of the prismatic battery assembly.

[0034] Figure 14 It is used for manufacturing Figures 12A-12C A schematic diagram of an exemplary method for a prismatic battery assembly.

[0035] Figures 15A-15C This is a view of another exemplary prismatic battery assembly having a current collector tab attached to a terminal lead tab that extends through a slot formed in the cap of the prismatic battery assembly and is attached to the terminal plate at or within the slot of the terminal plate.

[0036] Figure 16A yes Figures 15A-15C A cross-sectional view of the electrode stack and current collector tab of a prismatic battery assembly, wherein the current collector tab is attached to a two-piece terminal lead tab.

[0037] Figure 16B yes Figures 15A-15C A cross-sectional view of the electrode stack and current collector tab of a prismatic battery assembly, wherein the current collector tab is attached to a U-shaped terminal lead tab.

[0038] Figure 17 It is used for manufacturing Figures 15A-15C A schematic diagram of an exemplary method for a prismatic battery assembly.

[0039] In all the accompanying drawings, the corresponding reference numerals denote the corresponding parts. Detailed Implementation

[0040] The example configuration will now be described more fully with reference to the accompanying drawings. The example configuration is provided so that this disclosure will be thorough and will fully communicate the scope of this disclosure to those skilled in the art. Specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the configuration of this disclosure. It will be apparent to those skilled in the art that specific details are not required, the example configuration may be embodied in many different forms, and the specific details and example configuration should not be construed as limiting the scope of this disclosure.

[0041] The terminology used herein is for the purpose of describing a particular exemplary configuration only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may also be intended to include plural forms unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and therefore specify the presence of features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as requiring them to be performed in the specific order discussed or shown, unless specifically identified as such. Additional or alternative steps may be employed.

[0042] When an element or layer is referred to as “on another element or layer,” “joined to,” “connected to,” “attached to,” or “linked to” another element or layer, it may be directly on, joined to, attached to, or linked to the other element or layer, or there may be intermediate elements or layers present. Conversely, when an element is referred to as “directly on another element or layer,” “directly joined to,” “directly connected to,” “directly attached to,” or “directly linked to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0043] The terms “first,” “second,” “third,” etc., may be used herein to describe various elements, components, regions, layers, and / or parts. These elements, components, regions, layers, and / or parts should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or part from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms do not imply order or sequence. Therefore, without departing from the teachings of the example configuration, the first element, component, region, layer, or part discussed below may be referred to as the second element, component, region, layer, or part.

[0044] Referring now to the accompanying drawings, in which an example is described, vehicle 100 (such as an electric vehicle (EV) or a plug-in hybrid vehicle (PHEV) or a hybrid vehicle) includes a rechargeable prismatic battery assembly 102, such as a lithium-ion battery assembly, which is at least partially part of vehicle 100. Figure 1 and Figure 2 The battery 102 provides power to the propulsion system. The battery 102 includes a housing 104, such as a casing or shell, that houses multiple electrode stacks 106 or battery cells. The electrode stacks 106 receive and release current during operation of the battery 102, and the battery 102 is electrically connected to the propulsion system and / or other external circuitry of the vehicle 100 via a terminal block 108 disposed at or integrated with a cap assembly 110 of the battery housing 104.

[0045] Each electrode stack 106 of battery 102 includes a first current collector 112 or anode current collector electrically connected to a negative terminal 114 at a terminal plate 108, and a second current collector 116 or cathode current collector electrically connected to a positive terminal 118 at the terminal plate 108. For example, the anode current collector 112 is electrically connected to the negative terminal 114 via a corresponding tab 120 or anode current collector tab attached to a portion of the negative terminal 114 at a first side 122 or inside of the terminal plate 108. The cathode current collector 116 is electrically connected to the positive terminal 118 via a corresponding tab 124 or cathode current collector tab attached to a portion of the positive terminal 118 at an inside side 122 of the terminal plate 108. The anode current collector tab 120 and the cathode current collector tab 124 each extend from a first end 126 or edge of the electrode stack 106. Figure 2-4 As shown, the inner side 122 of the terminal plate 108 faces the first end 126 of the electrode stack 106 at the inner portion of the housing 104 and extends along the first end 126 of the electrode stack 106, and the second side 128 or outer side of the terminal plate 108 is opposite to the inner side 122. The corresponding portions of the negative terminal 114 and the positive terminal 118 provided on the outer side 128 of the terminal plate 108 are electrically connected to the external circuitry of the vehicle 100.

[0046] exist Figure 2-4 In the example shown, battery 102 includes two electrode stacks 106 electrically connected to terminal plate 108 via corresponding welds 130 formed between anode current collector tab 120 and negative terminal 114, and between cathode current collector tab 124 and positive terminal 118. Because the electrode stacks 106 are attached to the inner side 122 of terminal plate 108, the welds 130 are formed as the electrode stacks 106 move away from each other and as terminal plate 108 moves. Figure 4 In the example shown, the electrode stack 106 is in a generally horizontal orientation, with the respective ends 126 of the electrode stack 106 facing each other and towards the terminal plate 108 during welding. After the weld portion 130 is formed, the electrode stack 106 moves toward each other and toward a generally vertical orientation, with the respective ends 126 of the electrode stack 106 facing the inner side 122 of the terminal plate 108, and the electrode stack 106 and the terminal plate 108 are positioned at the battery assembly 102 in a generally vertical orientation. Figure 2 After the current collector tabs 120 and 124 are attached to the terminals 114 and 118, the movement of the electrode stack 106 can apply stress to the current collector tabs 120 and 124, thereby causing the electrode stack 106 to separate from the terminal plate 108.

[0047] In some examples, the battery casing of a prismatic battery assembly includes a cap and a terminal plate. The cap has a slot formed through it, and the terminal plate is disposed on the outside of the cap. Current collector tabs extend from the electrode stack and through the slot, and the current collector tabs are electrically connected to the terminal plate on the outside of the cap. See, for example, and see [reference needed]. Figures 5A to 5C , Figure 6A , Figure 6B and Figures 7 to 9The prismatic battery assembly 202 includes an electrode stack 206 having a plurality of current collector tabs, including at least one anode current collector tab 220 and at least one cathode current collector tab 224. The plurality of current collector tabs are electrically connected to corresponding current collectors 212 of the electrode stack 206 (e.g., including at least one anode current collector and at least one cathode current collector) and extend from a first end 226 or edge of the electrode stack 206. The battery assembly 202 includes a housing 204 that houses the electrode stack 206 and includes a cap 210 extending above and along the first end 226 of the electrode stack 206. The cap 210 has a first side 222 or inner side extending along and facing the first end 226 of the electrode stack 206, and a second side 228 or outer side opposite the inner side 222. The outer side 228 of the cap 210 is exposed to the outside of the battery assembly 202, and a terminal plate is disposed on the outer side 228 for electrically connecting the battery assembly 202 to the vehicle 100.

[0048] like Figures 5A-5C As shown, cap 210 includes a first terminal plate 214 or negative terminal plate disposed at outer side 228 and electrically connected to anode current collector tab 220, and a second terminal plate 218 or positive terminal plate disposed at outer side 228 and electrically connected to cathode current collector tab 224. As discussed further below, an opening is formed through cap 210, extending between inner side 222 and outer side 228, and a plurality of current collector tabs extend at least partially through or within the opening to be electrically connected to the terminal plate disposed at outer side 228 of cap 210. Although shown as a corresponding slot formed through cap 210, it should be understood that the opening may include any suitable slit, through-hole, or orifice formed through cap 210.

[0049] In the example shown, cap 210 includes a first slot 232 for receiving anode current collector tab 220 and a second slot 234 for receiving cathode current collector tab 224. Figure 6B The first slot 232 is aligned with the corresponding slot 236 formed through the negative terminal plate 214, and the second slot 234 is aligned with the corresponding slot 238 formed through the positive terminal plate 218. Figure 6A Therefore, when the anode current collector tab 220 extends through the first slot 232 of the cap 210 and the slot 236 of the negative terminal plate 214, and when the cathode current collector tab 224 extends through the second slot 234 of the cap 210 and the slot 238 of the positive terminal plate 218, the current collector tabs 220 and 224 can be disposed at the corresponding terminal plates 214 and 218 at the outer side 228 of the cap 210. Figure 7 ).

[0050] Furthermore, when the current collector tabs 220 and 224 are disposed through the slots 232 and 234 of the cap 210 and the slots 236 and 238 of the corresponding terminal plates 214 and 218, a first cover plate 240 may be disposed at the negative terminal plate 214 to cover the anode current collector tab 220 and seal the slots 232 and 236, and a second cover plate 242 may be disposed at the positive terminal plate 218 to cover the cathode current collector tab 224 and seal the slots 234 and 238. The current collector tabs 220 and 224 may extend at least partially along the corresponding terminal plates 214 and 218 between the cover plates 240 and 242 and the terminal plates 214 and 218. Therefore, current collector tabs 220, 224 extend through slots 232, 234 of cap 210 and slots 236, 238 of terminal plates 214, 218 to be electrically connected to terminal plates 214, 218 at an outer side 228 of cap 210, wherein cover plates 240, 242 are attached to terminal plates 214, 218 to hermetically seal housing 204.

[0051] In some examples, recesses are formed between each terminal plate and its corresponding cover plate to accommodate portions of current collector tabs disposed between the cover plate and the terminal plate. For example... Figure 8 As shown, the first terminal plate 214a or the first negative terminal plate includes a recess 244 (i.e., a terminal plate recess) formed adjacent to the slot 232 and extending partially through the upper surface of the terminal plate 214a. Therefore, when the anode current collector tab 220 is fed through the slot 232 and extends partially along the upper surface of the first terminal plate 214a, and when the planar first cover plate 240a is disposed at the first terminal plate 214a, the anode current collector tab 220 is received within the terminal plate recess 244 and electrically connected to the terminal plate 214a. The terminal plate recess 244 allows the lower surface of the planar first cover plate 240a to directly engage with and flush against the upper surface of the first terminal plate 214a to provide a more reliable seal between the cover plate 240a and the terminal plate 214a, as further discussed below.

[0052] Similarly, the second cover plate 240b may include a recess 246 (i.e., a cover plate recess) aligned with a slot 232 extending through the second terminal plate 214b or the second negative terminal plate. The second terminal plate 214b includes a flat upper surface, and the recess 246 extends partially through the second cover plate 240b from the lower surface of the cover plate 240b. Thus, when the anode current collector tab 220 is fed through the slot 232 and extends partially along the upper surface of the second terminal plate 214b, and when the second cover plate 240b is disposed at the second terminal plate 214b, the anode current collector tab 220 is received within the cover plate recess 246 and electrically connected to the terminal plate 214b. The cover plate recess 246 allows a peripheral region of the second cover plate 240b to engage the flat upper surface of the second terminal plate 214b to form a seal between the cover plate 240b and the terminal plate 214b without reducing the thickness of the conductive second terminal plate 214b.

[0053] Figure 9 A schematic diagram of an exemplary operational arrangement for a method 900 of manufacturing a prismatic battery assembly 202 is provided. Although Figure 9 It is shown that during the manufacture of battery assembly 202, the anode current collector tab 220 is attached to the negative terminal plate 214 at the outer side 228 of the cap 210. However, it should be understood that similar steps can be shown to show the attachment of the cathode current collector tab 224 to the positive terminal plate 218, and / or the attachment of the cathode current collector tab 224 to the positive terminal plate 218 can occur simultaneously with the attachment of the anode current collector tab 220 to the negative terminal plate 214.

[0054] At operation 902, method 900 includes providing a plurality of current collector tabs 220, 224 through at least one slot formed through a cap 210 passing through the battery housing 204. For example, method 900 includes feeding the anode current collector tab 220 through a first slot 232 of the cap 210 and feeding the cathode current collector tab 224 through a second slot 234 of the cap 210. In the illustrated example, method 900 also includes feeding the current collector tabs 220, 224 through slots 236, 238 of terminal plates 214, 218. Multiple current collector tabs 220, 224 are provided through slots 232, 234 of cap 210 and / or slots 236, 238 of terminal plates 214, 218. These tabs collect or gather current collector tabs 220, 224 between the holders 10 and move or lower cap 210 relative to end 226 of electrode stack 206 to feed current collector tabs 220, 224 through slots as holders 10 release current collector tabs 220, 224 and move out of the path of cap 210.

[0055] At operation 904, method 900 includes folding current collector tabs 220, 224 onto one side of the adjacent slots 236, 238 of terminal plates 214, 218. For example, method 900 includes folding the anode current collector tab 220 along the negative terminal plate 214 and folding the cathode current collector tab 224 along the positive terminal plate 218. Thus, with the plurality of current collector tabs 220, 224 disposed at least partially through the slots 232, 234 of cap 210 and the slots 236, 238 of terminal plates 214, 218, the current collector tabs 220, 224 extend at least partially along terminal plates 214, 218 at the outer side 228 of cap 210.

[0056] At operation 906, method 900 includes electrically connecting the plurality of current collector tabs 220, 224 at an outer 228 of the cap 210 to terminal plates 214, 218, wherein the plurality of current collector tabs 220, 224 are disposed through slots 232, 234 of the cap 210. In the illustrated example, this includes attaching covers 240, 242 to the terminal plates 214, 218 such that the covers 214, 218 extend over the slots 236, 238 of the plurality of current collector tabs 220, 224 and the terminal plates 214, 218, and attaching the plurality of current collector tabs 220, 224 to the terminal plates 214, 218 and / or the covers 240, 242. The electrically attached anode current collector tab 220 includes a first weld portion 248, such as a laser weld portion, between the anode current collector tab 220 and the negative terminal plate 214, and optionally further between the anode current collector tab 220 and the cover plate 240. The electrically attached cathode current collector tab 224 includes a second weld portion 250, such as a laser weld portion, between the cathode current collector tab 224 and the positive terminal plate 218, and optionally further between the cathode current collector tab 224 and the cover plate 242.

[0057] At operation 908, method 900 includes forming corresponding peripheral seals, such as peripheral laser welded portions, between cover plates 240, 242 and terminal plates 214, 218. For example, a first peripheral seal 252 is formed between the anode terminal plate 214 and the cover plate 240, and a second peripheral seal 254 is formed between the cathode terminal plate 218 and the cover plate 242. Peripheral seals 252 and 254 hermetically seal the battery casing 204.

[0058] In some examples, the current collector tab extends from the electrode stack and passes through a slot formed to pass through the cap and also through a slot formed to pass through a terminal plate disposed on the outside of the cap. The current collector tab is electrically connected to the terminal plate at or within the slot of the terminal plate. For example, and see... Figures 10A-10C and Figure 11The prismatic battery assembly 302 includes an electrode stack 306 having a plurality of current collector tabs, each current collector tab including at least one anode current collector tab 320 and at least one cathode current collector tab 324. The plurality of current collector tabs are electrically connected to corresponding current collectors 312 of the electrode stack 306 (e.g., including at least one anode current collector and at least one cathode current collector) and extend from a first end 326 or edge of the electrode stack 306. The battery assembly 302 includes a housing 304 that houses the electrode stack 306 and includes a cap 310 extending above and along the first end 326 of the electrode stack 306. The cap 310 has a first side 322 or inner side extending along and facing the first end 326 of the electrode stack 306, and a second side 328 or outer side opposite the inner side 322. The outer side 328 of the cap 310 is exposed to the outside of the battery assembly 302, and a terminal plate is disposed on the outer side 328 for electrically connecting the battery assembly 302 to the vehicle 100.

[0059] like Figures 10A-10C As shown, the cap 310 includes a first terminal plate 314 or negative terminal plate disposed at the outer side 328 and electrically connected to the anode current collector tab 320, and a second terminal plate 318 or positive terminal plate disposed at the outer side 328 and electrically connected to the cathode current collector tab 324. As discussed further below, an opening is formed through the cap 310 extending between the inner side 322 and the outer side 328, and a plurality of current collector tabs extend at least partially through or within the opening to be electrically connected to the terminal plate disposed at the outer side 328 of the cap 310. Although shown as a corresponding slot formed through the cap 310, it should be understood that the opening may include any suitable slit, through-hole, or orifice formed through the cap 310.

[0060] In the illustrated example, cap 310 includes a first slot 332 for receiving an anode current collector tab 320 and a second slot 334 for receiving a cathode current collector tab 324. The first slot 332 is aligned with a corresponding slot 336 formed through the negative terminal plate 314, and the second slot 334 is aligned with a corresponding slot 338 formed through the positive terminal plate 318. Therefore, when the anode current collector tab 320 extends through the first slot 332 of cap 310 and the slot 336 of negative terminal plate 314, and when the cathode current collector tab 324 extends through the second slot 334 of cap 310 and the slot 338 of positive terminal plate 318, the current collector tabs 320, 324 can be disposed at the corresponding terminal plates 314, 318 at the outer side 328 of cap 310.

[0061] When the current collector tabs 320 and 324 are arranged to pass through the slots 332 and 334 of the cap 310 and the slots 336 and 338 of the corresponding terminal plates 314 and 318, a first cover plate 340 can be provided at the negative terminal plate 314 to receive the anode current collector tab 320 and seal the slots 332 and 336, and a second cover plate 342 can be provided at the positive terminal plate 318 to receive the cathode current collector tab 324 and seal the slots 334 and 338. Figure 11 As shown, cover plates 340 and 342 are two-piece or clamping cover plates. Therefore, when current collector tabs 320 and 324 are positioned through slots 332 and 334 of cap 310 and through slots 334 and 338 of terminal plates 314 and 318, the current collector tabs 320 and 324 extend above terminal plates 314 and 318 and through slots or spaces between corresponding portions or sides of cover plates 340 and 342. The sides of the corresponding cover plates 340 and 342 are brought together to capture, clamp, or otherwise hold the current collector tabs 320 and 324 between them. The current collector tabs 320 and 324 are then electrically connected to terminal plates 314 and 318 by attaching them to or within slots 336 and 338 of terminal plates 314 and 318. For example, a first weld portion 348 (such as a laser weld portion) is formed between the anode current collector tab 320 and the slot 336 of the negative terminal plate 314, and a second weld portion 350 (such as a laser weld portion) is formed between the cathode current collector tab 324 and the slot 338 of the positive terminal plate 318. The first weld portion 348 and the second weld portion 350 can be filled with fillet wire to fill the gaps between the current collector tabs 320, 324 and the slots 336, 338 and to hermetically seal the housing 304.

[0062] Figure 11 A schematic diagram of an exemplary operational arrangement for a method 1100 of manufacturing a prismatic battery assembly 302 is provided. Although Figure 11 It is shown that during the manufacture of battery assembly 302, the anode current collector tab 320 is attached to the negative terminal plate 314 at the outer side 328 of the cap 310. However, it should be understood that similar steps can be shown to show the attachment of the cathode current collector tab 324 to the positive terminal plate 318, and / or the attachment of the cathode current collector tab 324 to the positive terminal plate 318 can occur simultaneously with the attachment of the anode current collector tab 320 to the negative terminal plate 314.

[0063] At operation 1102, method 1100 includes providing a plurality of current collector tabs 320, 324 through at least one slot formed through a cap 310 of the battery housing 304. For example, method 1100 includes feeding the anode current collector tab 320 through a first slot 332 of the cap 310 and feeding the cathode current collector tab 324 through a second slot 334 of the cap 310. In the illustrated example, method 1100 also includes feeding the current collector tabs 320, 324 through slots 336, 338 of the terminal plates 314, 318. Multiple current collector tabs 320, 324 are provided through slots 332, 334 of cap 310 and / or slots 336, 338 of terminal plates 314, 318. These tabs collect or gather current collector tabs 320, 324 between the holders 10 and move or lower cap 310 relative to end 326 of electrode stack 306 to feed current collector tabs 320, 324 through slots when holders 10 release current collector tabs 320, 324 and move out of the path of cap 310.

[0064] At operation 1104, method 1100 includes applying two-piece or clamping cover plates 340, 342 to terminal plates 314, 318 such that current collector tabs 320, 324 are disposed between corresponding sides or portions of cover plates 340, 342. For example, a first cover plate 340 is disposed at the negative terminal plate 314, wherein the anode current collector tab 320 is disposed between corresponding sides or portions of cover plate 340, and a second cover plate 342 is disposed at the positive terminal plate 318, wherein the cathode current collector tab 324 is disposed between corresponding sides or portions of cover plate 342. Cover plates 340, 342 can be pressed or clamped together to capture or retain the current collector tabs 320, 324 between the sides or portions of the respective cover plates 340, 342.

[0065] At operation 1106, method 1100 includes electrically connecting the plurality of current collector tabs 320, 324 at or within the slots 332, 334 of the cap 310, wherein the plurality of current collector tabs 320, 324 pass through the slots 332, 334 of the cap 310 and are disposed between portions of the respective cover plates 340, 342. In the illustrated example, this includes trimming the ends of the current collector tabs 320, 324 and attaching the plurality of current collector tabs 320, 324 to the slots 332, 334 of the terminal plates 314, 318, and attaching the plurality of current collector tabs 320, 324 to the cover plates 340, 342. The electrically attached anode current collector tab 320 includes a slot 336 between the anode current collector tab 320 and the negative terminal plate 314, and optionally further forms a first weld portion 348, such as a laser weld portion, between the anode current collector tab 320 and the cover plate 340. The electrically attached cathode current collector tab 324 includes a slot 338 between the cathode current collector tab 324 and the positive terminal plate 318, and optionally further forms a second weld portion 350, such as a laser weld portion, between the cathode current collector tab 324 and the cover plate 342.

[0066] At operation 1108, method 1100 includes forming corresponding peripheral seals, such as peripheral laser welded portions, between cover plates 340, 342 and terminal plates 314, 318. For example, a first peripheral seal 352 is formed between the anode terminal plate 314 and the cover plate 340, and a second peripheral seal 354 is formed between the cathode terminal plate 318 and the cover plate 342. Peripheral seals 352, 354 can hermetically seal the battery casing 304.

[0067] Optionally, a current collector tab extends from the electrode stack and passes through a slot formed through the cap, and also through a slot formed through a terminal plate disposed on the outside of the cap. The current collector tab is electrically connected to the terminal plate at or within the slot of the terminal plate without using a cover plate to seal the slot of the terminal plate. For example, and see [link to relevant documentation]. Figures 12A-12C , Figure 13 and Figure 14The prismatic battery assembly 402 includes an electrode stack 406 having a plurality of current collector tabs, the current collector tabs including at least one anode current collector tab 420 and at least one cathode current collector tab 424. The plurality of current collector tabs are electrically connected to corresponding current collectors 412 of the electrode stack 406 (e.g., including at least one anode current collector and at least one cathode current collector) and extend from a first end 426 or edge of the electrode stack 406. The battery assembly 402 includes a housing 404 that houses the electrode stack 406 and includes a cap 410 extending above and along the first end 426 of the electrode stack 406. The cap 410 has a first side 422 or inner side extending along and facing the first end 426 of the electrode stack 406, and a second side 428 or outer side opposite the inner side 422. The outer side 428 of the cap 410 is exposed to the outside of the battery assembly 402, and a terminal block is disposed on the outer side 428 for electrically connecting the battery assembly 402 to the vehicle 100.

[0068] like Figures 12A-12C As shown, the cap 410 includes a first terminal plate 414 or negative terminal plate disposed at the outer side 428 and electrically connected to the anode current collector tab 420, and a second terminal plate 418 or positive terminal plate disposed at the outer side 428 and electrically connected to the cathode current collector tab 424. An opening is formed through the cap 410, extending between the inner side 422 and the outer side 428, and a plurality of current collector tabs extend at least partially through or within the opening to be electrically connected to the terminal plate disposed at the outer side 428 of the cap 410. Although shown as a corresponding slot formed through the cap 410, it should be understood that the opening may include any suitable slit, through-hole, or orifice formed through the cap 410.

[0069] In the illustrated example, cap 410 includes a first slot 432 for receiving an anode current collector tab 420 and a second slot 434 for receiving a cathode current collector tab 424. The first slot 432 is aligned with a corresponding slot 436 formed through the negative terminal plate 414, and the second slot 434 is aligned with a corresponding slot 438 formed through the positive terminal plate 418. Figure 13Therefore, when the anode current collector tab 420 extends through the first slot 432 of the cap 410 and the slot 436 of the negative terminal plate 414, and when the cathode current collector tab 424 extends through the second slot 434 of the cap 410 and the slot 438 of the positive terminal plate 418, the current collector tabs 420, 424 can be disposed at the corresponding terminal plates 414, 418 at the outer side 428 of the cap 410. That is, the current collector tabs 420, 424 extend through the slots 436, 438 of the terminal plates 414, 418 and extend partially above and / or along the outer side of the terminal plates 414, 418. This allows the current collector tabs 420, 424 to be directly attached to or within the slots 436, 438 of the terminal plates 414, 418, and to seal the battery housing 404 without the need for a cover plate, as discussed further below. For example, a first weld portion 448, such as a laser weld portion, is formed between the anode current collector tab 420 and the slot 436 of the negative terminal plate 414, and a second weld portion 450, such as a laser weld portion, is formed between the cathode current collector tab 424 and the slot 438 of the positive terminal plate 418. During the welding of the current collector tabs 420, 424 to the slots 436, 438 of the terminal plates 414, 418, filler can be used to fill the gaps and seal the housing 404.

[0070] Figure 14 A schematic diagram of an exemplary operational arrangement for a method 1400 of manufacturing a prismatic battery assembly 402 is provided. Although Figure 14 It is shown that during the manufacture of battery assembly 402, the anode current collector tab 420 is attached to the negative terminal plate 414 at the outer side 428 of the cap 410. However, it should be understood that similar steps can be shown to show the attachment of the cathode current collector tab 424 to the positive terminal plate 418, and / or the attachment of the cathode current collector tab 424 to the positive terminal plate 418 can occur simultaneously with the attachment of the anode current collector tab 420 to the negative terminal plate 414.

[0071] At operation 1402, method 1400 includes distributing a plurality of current collector tabs 420, 424 through at least one slot formed through a cap 410 of the battery housing 404. For example, method 1400 includes feeding an anode current collector tab 420 through a first slot 432 of the cap 410 and feeding a cathode current collector tab 424 through a second slot 434 of the cap 410. In the illustrated example, method 1400 also includes feeding the current collector tabs 420, 424 through slots 436, 438 of terminal plates 414, 418. Multiple current collector tabs 420, 424 are provided through slots 432, 434 of cap 410 and / or slots 436, 438 of terminal plates 414, 418. These tabs collect or gather current collector tabs 420, 424 between holders 10 and move or lower cap 410 relative to end 426 of electrode stack 406 to feed current collector tabs 420, 424 through slots as holders 10 release current collector tabs 420, 424 and move out of the path of cap 410.

[0072] With current collector tabs 420, 424 extending through slots 436, 438 of terminal plates 414, 418, the current collector tabs 420, 424 extend at least partially above the upper surfaces of terminal plates 414, 418. Therefore, at operation 1404, method 1400 may include trimming the current collector tabs 420, 424 such that the ends of the current collector tabs 420, 424 may extend planar with or only slightly above the upper surfaces of terminal plates 414, 418. In other words, the end of the anode current collector tab 420 may be located at or near the upper surface of the negative terminal plate 414, and the end of the cathode current collector tab 424 may be located at or near the upper surface of the positive terminal plate 418.

[0073] At operation 1406, method 1400 includes electrically connecting the plurality of current collector tabs 420, 424 at an outer 428 of the cap 410, wherein the plurality of current collector tabs 420, 424 are disposed through slots 432, 434 of the cap 410. In the illustrated example, the plurality of current collector tabs 420, 424 are attached to the terminal plates 414, 418 at or within slots 436, 438. Electrically attaching the anode current collector tab 420 includes using filler lines at or within slots 436 of the negative terminal plate 414 and forming a first weld portion 448, such as a laser weld portion, between the anode current collector tab 420 and the negative terminal plate 414. The electrically attached cathode current collector tab 424 includes a filler line at or within a slot 438 of the positive terminal plate 418 and forms a second weld portion 450, such as a laser weld portion, between the cathode current collector tab 424 and the positive terminal plate 418. The first weld portion 448 and the second weld portion 450 can hermetically seal the battery housing 404. Optionally, corresponding peripheral seals 452, 454, such as peripheral laser weld portions, can be formed between the terminal plates 414, 418 and the cap 410.

[0074] In some examples, a terminal plate on the outside of the cap is electrically connected to terminal leads or lead tabs that extend partially within a slot in the cap. Current collector tabs extend from the electrode stack and partially along, within, or through the slot, and attach to the terminal leads within the slot to electrically connect the current collector to the terminal plate on the outside of the cap. See, for example, and see also... Figures 15A to 15C , Figure 16A , Figure 16B and Figure 17The prismatic battery assembly 502 includes an electrode stack 506 having a plurality of current collector tabs, including at least one anode current collector tab 520 and at least one cathode current collector tab 524. The plurality of current collector tabs are electrically connected to corresponding current collectors 512 of the electrode stack 506 (e.g., including at least one anode current collector and at least one cathode current collector) and extend from a first end 526 or edge of the electrode stack 506. The battery assembly 502 includes a housing 504 that houses the electrode stack 506 and includes a cap 510 extending above and along the first end 526 of the electrode stack 506. The cap 510 has a first side 522 or inner side extending along and facing the first end 526 of the electrode stack 506, and a second side 528 or outer side opposite the inner side 522. The outer side 528 of the cap 510 is exposed to the outside of the battery assembly 502, and a terminal plate is disposed on the outer side 528 for electrically connecting the battery assembly 502 to the vehicle 100.

[0075] like Figures 15A-15C As shown, cap 510 includes a first terminal plate 514 or negative terminal plate disposed at outer side 528 and electrically connected to anode current collector tab 520, and a second terminal plate 518 or positive terminal plate disposed at outer side 528 and electrically connected to cathode current collector tab 524. As discussed further below, an opening is formed through cap 510, extending at least partially between inner side 522 and outer side 528, and a plurality of current collector tabs extend partially through or within the opening to be electrically connected to the terminal plate disposed at outer side 528 of cap 510. Although shown as a corresponding slot formed through cap 510, it should be understood that the opening may include any suitable slit, through-hole, or orifice formed through cap 510 at least partially.

[0076] In the illustrated example, cap 510 includes a first slot 532 for receiving an anode current collector tab 520 and a second slot 534 for receiving a cathode current collector tab 524. The first slot 532 is aligned with a negative terminal plate 514, and the second slot 534 is aligned with a positive terminal plate 518. A first terminal lead 556 or a negative terminal lead tab is electrically connected to the negative terminal plate 514 and extends partially within the first slot 532 from the negative terminal plate 514 toward a first end 526 of the electrode stack 506. A second terminal lead 558 or a positive terminal lead tab is electrically connected to the positive terminal plate 518 and extends partially within the second slot 534 from the positive terminal plate 518 toward the first end 526 of the electrode stack 506. A negative terminal lead tab 556 is attached to or within a first slot 532 to an anode current collector tab 520 for electrically connecting the anode current collector tab 520 and the negative terminal plate 514. A positive terminal lead tab 558 is attached to or within a second slot 534 to a cathode current collector tab 524 for electrically connecting the cathode current collector tab 524 and the positive terminal plate 518. The negative terminal plate 514 may be attached to a cap 210 to hermetically seal the first slot 536, and the positive terminal plate 518 may be attached to a cap 210 to hermetically seal the second slot 538. In some examples, a first cover plate 540 is disposed at the negative terminal plate 514, and a second cover plate 542 is disposed at the positive terminal plate 518 to seal the housing 504.

[0077] Any suitable conductive terminal lead tab can be used to attach between multiple current collector tabs and terminal blocks. For example... Figure 16A As shown, the first terminal lead tab 556a or the first negative terminal lead tab is a two-piece or clamping terminal lead tab that receives multiple current collector tabs between corresponding sides or portions of the terminal lead tab 556a. The two sides or portions of the terminal lead tab 556a are pressed together or clamped to hold the multiple current collector tabs there. Figure 16B As shown, the second terminal lead tab 556b or the second negative terminal lead tab is a U-shaped terminal lead tab that receives multiple current collector tabs between corresponding legs or portions of the U-shaped terminal lead tab 556b. The two legs or portions of the U-shaped terminal lead tab 556b are pressed together, crimped, or clamped to hold the multiple current collector tabs therein.

[0078] Furthermore, multiple current collector tabs are welded to corresponding terminal lead tabs, such as via laser welding or ultrasonic welding, to electrically connect the multiple current collector tabs and terminal lead tabs. For example, a first weld portion 548 is formed between the anode current collector tab 520 and the negative terminal lead tab 556, and a second weld portion 550 is formed between the cathode current collector tab 524 and the positive terminal lead tab 558.

[0079] Figure 17 A schematic diagram of an exemplary operational arrangement for a method 1700 of manufacturing a prismatic battery assembly 502 is provided. Although Figure 17 It is shown that during the manufacture of battery assembly 502, the anode current collector tab 520 is attached to the negative terminal plate 514 via the negative terminal lead tab 556. However, it should be understood that similar steps can be shown to show the cathode current collector tab 524 being attached to the positive terminal plate 518 via the positive terminal lead tab 558, and / or the attachment of the cathode current collector tab 524 to the positive terminal lead tab 558 and the positive terminal plate 518 can occur simultaneously with the attachment of the anode current collector tab 520 to the negative terminal lead tab 556 and the negative terminal plate 514.

[0080] At operation 1702, method 1700 includes attaching a plurality of current collector tabs 520, 524 to terminal lead tabs 556, 558, as discussed above. For example, method 1700 includes attaching an anode current collector tab 520 to a negative terminal lead 556 and attaching a cathode current collector tab 524 to a positive terminal lead 558.

[0081] When multiple current collector tabs 520, 524 are attached to terminal lead tabs 556, 558, method 1700 includes, at operation 1704, configuring the multiple current collector tabs 520, 524 and / or terminal lead tabs 556, 558 to partially pass through slots 532, 534 formed through a cap 510 of the battery housing 504. For example, method 1700 includes feeding the anode current collector tab 520 and the negative terminal lead tab 556 through a first slot 532 of the cap 510, and feeding the cathode current collector tab 524 and the positive terminal lead tab 558 through a second slot 534 of the cap 510. In the illustrated example, method 1700 also includes feeding the terminal lead tabs 556, 558 through slots 536, 538 of terminal plates 514, 518. Multiple current collector tabs 520, 524 are provided through slots 532, 534 of cap 510 and / or slots 536, 538 of terminal plates 514, 518, including collecting or gathering terminal lead tabs 556, 558 between holders 10 and moving or lowering cap 510 relative to end 526 of electrode stack 506 to feed terminal lead tabs 556, 558 and current collector tabs 520, 524 at least partially through slots.

[0082] At operation 1706, method 1700 includes attaching terminal lead tabs 556, 558 to terminal plates 514, 518 to electrically connect the plurality of current collector tabs 520, 524 and the corresponding terminal plates 514, 518, with terminal lead tabs 556, 558 disposed through slots 532, 534 of cap 510. In the illustrated example, this includes passing the terminal lead tabs 556, 558 at least partially through slots 536, 538 of terminal plates 514, 518 and welding (such as laser welding or ultrasonic welding) the terminal lead tabs 556, 558 to terminal plates 514, 518. Therefore, the first weld 560 between the negative terminal lead tab 556 and the negative terminal plate 514 electrically connects the anode current collector tab 520 and the negative terminal plate 514, and the second weld 562 between the positive terminal lead tab 558 and the positive terminal plate 518 electrically connects the cathode current collector tab 524 and the positive terminal plate 518. The clamp 10 can hold the terminal lead tabs 556, 558 during welding and release the terminal lead tabs 556, 558 after welding. The first weld 560 and the second weld 562 can hermetically seal the housing 504 of the battery assembly 502.

[0083] Optionally, at operation 1708, method 1700 includes positioning cover plates 540, 542 at terminal plates 514, 518, and forming corresponding peripheral seals, such as peripheral laser welded portions, between cover plates 540, 542 and terminal plates 514, 518. Cover plates 540, 542 may extend over and along the first welded portion 560 and the second welded portion 562. Therefore, a first peripheral seal 552 is formed between the anode terminal plate 514 and the cover plate 540, and a second peripheral seal 554 is formed between the cathode terminal plate 518 and the cover plate 542. Peripheral seals 552, 554 ensure an airtight seal for the battery casing 504.

[0084] Therefore, because the current collector tabs extend at least partially through slots formed in the cap of the battery casing for electrical connection to the terminal block at the outside of the cap, bending of the current collector tabs during battery manufacturing is reduced. This improves the integrity of the physical and electrical connections within the battery assembly. Furthermore, the shortened electrical path between the current collector and the battery terminals allows for a reduction in the space or height between the cap and the electrode stack, thus improving battery encapsulation efficiency.

[0085] Many embodiments have been described. However, it should be understood that various modifications can be made without departing from the spirit and scope of this disclosure. Therefore, other embodiments are within the scope of the appended claims.

[0086] The foregoing description is provided for illustrative and descriptive purposes. It is not intended to be exhaustive or limiting of this disclosure. Elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable where applicable and can be used in selected configurations, even if not specifically shown or described. They can also be varied in many ways. Such variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A method for manufacturing a prismatic battery module, the method comprising: A plurality of current collector tabs are configured to pass at least partially through a slot in a cap of a housing, the plurality of current collector tabs being electrically connected to a corresponding current collector of an electrode stack and extending from an end of the electrode stack, the housing accommodating the electrode stack, the cap having an inner side extending along an end of the electrode stack and an outer side opposite to the inner side, and the slot being formed through the cap between the outer side and the inner side; In the case where multiple current collector tabs are configured to at least partially pass through the slot, the multiple current collector tabs are electrically connected to a terminal plate located on the outside of the cap; as well as With multiple current collector tabs electrically connected to the terminal block, the housing is hermetically sealed.

2. The method of claim 1, wherein configuring the plurality of current collector tabs to at least partially pass through the slot comprises: Collects multiple current collector tabs; as well as The cap is moved relative to the end of the electrode stack to feed the plurality of current collector tabs at least partially through the slot.

3. The method of claim 1, wherein, with the plurality of current collector tabs configured to at least partially pass through the slot, the plurality of current collector tabs extend through the slot of the cap and extend at least partially along the terminal plate at the outside of the cap, the plurality of current collector tabs being disposed between the terminal plate and the cover plate, the cover plate hermetically sealing the housing.

4. The method of claim 3, wherein, in the case where the plurality of current collector tabs extend at least partially along the terminal plate, the plurality of current collector tabs are received within a recess formed between the terminal plate and the cover plate.

5. The method of claim 4, wherein the recess extends in part into one of the group consisting of: (i) a terminal plate and (ii) a cover plate.

6. The method of claim 1, wherein, in the case where the plurality of current collector tabs are configured to at least partially pass through the slot, the plurality of current collector tabs extend through the slot of the cap, and the plurality of current collector tabs extend at least partially through the slot of the terminal plate.

7. The method of claim 6, wherein electrically connecting the plurality of current collector tabs to the terminal block comprises attaching the plurality of current collector tabs to the terminal block at a slot in the terminal block.

8. The method of claim 7 further comprises attaching a cover plate to a terminal plate, the cover plate extending over a plurality of current collector tabs and slots in the terminal plate, and the cover plate hermetically sealing the housing.

9. The method of claim 1, wherein electrically connecting the plurality of current collector tabs to the terminal block comprises attaching the plurality of current collector tabs to lead tabs electrically connected to the terminal block and extending within a slot in the cap.

10. The method of claim 1, wherein electrically connecting the plurality of current collector tabs to the terminal block comprises laser welding the plurality of current collector tabs to the terminal block.

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