Battery cover assembly

Abstract

A battery cover assembly is provided. A vehicle, a battery assembly, and a method for manufacturing a battery are provided. A method for manufacturing a battery includes: arranging a plurality of foils associated with a plurality of electrodes of a battery cell in a stack, wherein the stack has an outside surface; positioning a cap assembly over the stack, where the cap assembly has an outside surface, and where the cap assembly includes a conductive terminal electrically connected with the battery cell tab, where an insulating plate is located between the battery cell tab and the conductive terminal; coupling battery cell tabs to the plurality of foils; and adhering an insulating tape to an outer side surface of the stack and an outer side surface of the cover assembly.

Description

Technical Field

[0001] This disclosure generally relates to assembly strategies for batteries, and more specifically to battery assemblies that provide an insulating bond between a battery cover and a foil associated with the electrodes of the battery cell. Background Technology

[0002] Lithium-ion and related batteries are used in automotive and related transportation applications, serving as a supplement to conventional internal combustion engines (ICE) in the case of hybrid electric vehicles (HEVs) or as an alternative to conventional ICE in the case of pure electric vehicles (EVs). The ability to passively store energy from stationary and portable sources, as well as from recovered kinetic energy provided by the vehicle and its components, makes such batteries ideally suited for use as part of the propulsion systems of cars, trucks, buses, motorcycles, and related vehicle platforms. The flow of current to and from individual cells (i.e., individual electrochemical units) allows the current or voltage to be increased to generate the desired power output when several such cells are combined into larger, successive components (such as modules and groups). In this context, larger modules and groups consist of one or more cells connected in series (for increasing voltage), in parallel (for increasing current), or both, and may include additional structures to ensure proper installation and operation of these cells. One common vehicle form of battery pack is called a power battery, while another is called an energy battery.

[0003] In one form, the individual cells that make up the battery pack are configured as rectangular (i.e., prismatic) cans, which define a rigid outer casing called a cell box. These types of cells are often assembled into power battery pack variants. Furthermore, these cells can be arranged face-to-face (like a deck of cards) along a stacking axis formed by aligned, parallel plate-like surfaces. Positive and negative terminals on one edge of the outer casing of each cell are laterally spaced from each other to act as electrical contacts for connection (e.g., via a bus bar) to an external load or circuit. Battery cells may contain thin metal sheets as electrode substrates, or simply electrode plates, to generate current flow. These electrode plates contain extensions, called tabs, that extend to the outside of the cell bag and are used to connect the electrode plates to conductors or buses made of copper or a metal alloy or aluminum or a metal alloy during battery assembly. Two types of tab materials are commonly used in battery construction: aluminum and copper. In some cases, copper tabs and / or copper conductors may be coated with a thin layer of nickel to enhance corrosion resistance. In some cases, aluminum tabs and / or aluminum conductors may have a thin anodization layer.

[0004] Ultrasonic metal welding has been used to join thin tab materials to conductors. It enables the joining of dissimilar metals and can join materials with significant differences in sheet thickness. Laser welding is another process used. This process allows for strong, consistent welds in small areas.

[0005] Typically, the process of attaching tab material to the conductor utilizes the space beneath a cover assembly that seals the battery cell within the battery casing. Providing a cover assembly that facilitates an insulating connection between the cover assembly and the cell stack would be advantageous.

[0006] Accordingly, there is a need for apparatus and methods for manufacturing or assembling batteries that provide an insulating connection between the cover assembly and the cell stack. Furthermore, other desirable features and characteristics of this disclosure will become apparent from the accompanying drawings and the foregoing technical and background information, based on the following detailed description and the appended claims. Summary of the Invention

[0007] In one embodiment, a method for manufacturing a battery includes: arranging a plurality of foils associated with a plurality of electrodes of battery cells in a stack, wherein the stack has an outer surface; positioning a cover assembly over the stack, wherein the cover assembly has an outer surface and wherein the cover assembly includes conductive terminals electrically connected to battery cell tabs, wherein an insulating plate is located between the battery cell tabs and the conductive terminals; coupling the battery cell tabs to the plurality of foils; and adhering insulating tape to the outer surface of the stack and the outer surface of the cover assembly.

[0008] In some embodiments of the method, attaching the battery cell tabs to multiple foils is performed before adhering the insulating tape to the outer surfaces of the stack and the outer surfaces of the cover assembly.

[0009] In some embodiments of the method, attaching the battery cell tabs to multiple foils is performed after adhering insulating tape to the outer surfaces of the stack and the outer surfaces of the cover assembly.

[0010] In some embodiments of the method, attaching the battery cell tabs to multiple foils includes laser welding the battery cell tabs to the multiple foils.

[0011] In some embodiments of the method, a first direction is defined by the connection from the conductive terminal to the battery cell tab; the insulating plate includes a body extending between lateral edges in a second direction perpendicular to the first direction; the insulating plate also includes legs extending from the lateral edges to a distal end; and the legs form the outer surface of the cover assembly.

[0012] In some embodiments of the method, the legs are pivotally connected to the body via hinges, and the method includes moving the legs from an outwardly extending configuration to a downwardly extending configuration before adhering insulating tape to the outer surfaces of the stacked outer surfaces and the outer surfaces of the cover assembly.

[0013] In some embodiments, the method further includes attaching the legs to the body before adhering the insulating tape to the outer surfaces of the stack and the outer surfaces of the cover assembly.

[0014] In some embodiments, the method further includes attaching legs to the body after the battery cell tabs are attached to the plurality of foils and before the insulating tape is adhered to the outer surfaces of the stack and the outer surfaces of the cover assembly.

[0015] In some embodiments of the method, the legs are integrally formed with the body and are fixed in a downwardly extending configuration.

[0016] In some embodiments of the method, the height of the outer surface of the cover assembly is at least 10 mm.

[0017] In another embodiment, a battery assembly is provided, comprising: a plurality of foils associated with a plurality of electrodes of battery cells in a stack, wherein the stack has an outer surface; a cover assembly situated above the stack; and an insulating tape adhered to the outer surface of the stack and the outer surface of the cover assembly. The cover assembly includes: battery cell tabs electrically connected to the plurality of foils; conductive terminals electrically connected to the battery cell tabs; and an insulating plate between the battery cell tabs and the conductive terminals, wherein the insulating plate includes a laterally extending body and downwardly extending legs, and wherein the cover assembly has an outer surface formed by the legs.

[0018] In some embodiments of this battery assembly, downward-extending legs are connected to the body via hinges.

[0019] In some embodiments of this battery assembly, the downwardly extending legs are connected to the body via friction fitting.

[0020] In some embodiments of the battery assembly, the downward-extending legs are integrally formed with the main body.

[0021] In some embodiments, the battery assembly also includes a rigid housing, and multiple foils and multiple electrodes are positioned within the rigid housing.

[0022] In another embodiment, a vehicle is provided, comprising: an electric motor configured to provide drive torque; and a battery system operatively connected to and operated to provide power to the electric motor. The battery system includes: a housing surrounding an interior space; a plurality of foils associated with a plurality of electrodes of battery cells received in a stack within the interior space, wherein the stack has an outer surface; a cover assembly situated above the stack; and an insulating tape adhered to the outer surface of the stack and the outer surface of the cover assembly. The cover assembly includes: battery cell tabs electrically coupled to the plurality of foils; conductive terminals electrically connected to the battery cell tabs; and an insulating plate between the battery cell tabs and the conductive terminals. The insulating plate includes a laterally extending body and downwardly extending legs, and the cover assembly has an outer surface formed by the downwardly extending legs.

[0023] In some embodiments of the vehicle, the downwardly extending outriggers are hinged to the laterally extending body.

[0024] In some embodiments of the vehicle, the downwardly extending outriggers are connected to the laterally extending body via friction engagement.

[0025] In some embodiments of the vehicle, the downwardly extending outriggers are integrally formed with the laterally extending body.

[0026] In some embodiments of the vehicle, the insulating plate includes a cover having a first lateral length and an insert having a second lateral length less than the first lateral length, the insert forming part of the outer surface of the cover assembly. Attached Figure Description

[0027] The present disclosure will be described below with reference to the following figures, wherein the same numerals denote the same elements, and wherein:

[0028] Figure 1 This is a schematic perspective view of an electric vehicle according to an exemplary embodiment, the electric vehicle having a cut-out portion to expose a battery housed in a battery casing.

[0029] Figure 2 This is according to an exemplary embodiment. Figure 1 A perspective view of the battery.

[0030] Figure 3 This is according to an exemplary embodiment. Figure 2 A cross-sectional schematic diagram of the battery cover assembly.

[0031] Figure 4 yes Figure 3 A top view of the cover assembly.

[0032] Figure 5 This is according to an exemplary embodiment. Figure 2 A schematic diagram of the end of the battery cover assembly.

[0033] Figure 6 and Figure 7 This is an example of an installed and uninstalled configuration shown according to an exemplary embodiment. Figure 5 A cross-sectional schematic diagram of an embodiment of the insulating insert of the cover assembly.

[0034] Figure 8 and Figure 9 This is an example of an installed and uninstalled configuration shown according to an exemplary embodiment. Figure 5 A cross-sectional schematic diagram of an embodiment of the insulating insert of the cover assembly.

[0035] Figure 10 It is a single configuration according to an exemplary embodiment. Figure 5 A perspective view of an embodiment of the insulating insert of the cover assembly.

[0036] Figure 11 This is a flowchart illustrating a method for assembling a battery according to certain embodiments. Detailed Implementation

[0037] The following detailed description is merely exemplary in nature and is not intended to limit the application and use of the embodiments described herein. Furthermore, it is not intended to be bound by any express or implied theory presented in the foregoing introduction, summary of the invention, or the following detailed description.

[0038] This document describes embodiments of the present disclosure in terms of functional and / or logic block components and various processing steps. Connecting lines shown in the various figures included herein are intended to illustrate exemplary functional relationships and / or physical couplings between various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in the embodiments of the present disclosure.

[0039] For the purposes of this description, unless expressly denied, the use of the singular includes the plural and vice versa; the terms “and” and “or” should be both connective and selective; and the words “including,” “contains,” “comprising,” “containing,” “having,” etc., should mean “including but not limited to.” Furthermore, approximate words such as “approximately,” “almost,” “substantially,” “generally,” “roughly,” etc., may be used herein in the sense of “being, near, or almost being,” or “within 0-5%,” or “within acceptable manufacturing tolerances,” or logical combinations thereof. As used herein, a component “configured” to perform the specified function is capable of performing the specified function without alteration, rather than merely having the potential to perform the specified function after further modification. In other words, when explicitly configured to perform the specified function, the described hardware is specifically selected, created, implemented, utilized, programmed, and / or designed to perform the specified function.

[0040] The embodiments described herein provide a method for connecting electrode stacks and battery cover assemblies using insulating tape to prevent damage to prismatic battery cells, such as due to short circuits, misalignment, or other quality issues. In the embodiments described herein, the insulating tape is applied directly to an insulating insert located beneath and securely held by a conductive cover plate. The embodiments described herein ensure that the connection between the stacked battery cells and the cover assembly is completely covered by the insulating tape. Specifically, the interface between the stacked battery cells and the cover assembly is surrounded by the insulating tape.

[0041] Referring to the accompanying drawings, where similar reference numerals correspond as far as possible to similar or analogous parts throughout the various drawings, Figure 1 The image shows an electric vehicle 100 having a battery module 200 (such as a battery cell or a battery pack containing multiple battery cells). The term "battery" as used herein may refer to a battery module, a battery cell, or a stack of cells. The term "battery pack" as used herein may refer to both the battery and the battery housing system in which the battery is housed.

[0042] Figure 1 The electric vehicle 100 is represented as an automobile, such as any of several different types of automobiles, such as, for example, a sedan, van, truck, sport utility vehicle (SUV), etc. In some implementations, vehicle 100 may include a motorcycle or other land-based vehicle (such as a rail locomotive), or a non-land-based vehicle (such as an aircraft, spacecraft, ship, etc.), and / or one or more other types of mobile platforms (e.g., a robot and / or another mobile platform). In other implementations, battery module 200 may alternatively be part of and / or coupled to any number of other types of mobile or non-mobile platforms and / or other systems, such as buildings, infrastructure, secondary uses, home power, non-automobile, and / or other platforms and / or other systems.

[0043] The electric vehicle 100 shown includes a vehicle chassis 112. A battery module 200 is provided with a battery tray 114. The battery module 200 can be attached to the battery tray 114, which in turn can be attached to the vehicle chassis 112 to secure the battery module 200 to the electric vehicle 100.

[0044] The electric vehicle 100 may also include a battery disconnection unit 116 connected to the battery 200 and providing electrical communication between the battery 200 and the electrical system (not shown) of the electric vehicle 10.

[0045] The battery module 200 is also provided with a battery cover 118 extending above and around the battery 200. The battery cover 118 protects the battery 200 from damage and provides electrical insulation for the high voltage of the battery 200.

[0046] In an exemplary embodiment, the battery module 200 is an assembly of battery cells.

[0047] Figure 2 Schematic map shows Figure 1 A perspective view of the battery cell 210 of the battery module 200. Specifically, Figure 2 The figure shows a prismatic battery cell 210.

[0048] The prismatic battery cell 210 is shown as including an outer casing or housing 220 that surrounds and defines an internal space 225 within the housing 220. The exemplary housing 220 may be conductive. For example, the housing 220 may be metallic. In some embodiments, the housing 220 is aluminum. The illustrated housing 220 is a rectangular polyhedron and includes relatively short side-facing faces 222 and relatively long side-facing faces 224.

[0049] As shown in the figure, the housing 220 may be formed with an open end, which is covered or closed by a cover 230. In some embodiments, the cover 230 may be part of the housing 220. In some embodiments, the cover 230 is conductive. For example, the cover 230 may be metallic, such as aluminum or an aluminum alloy.

[0050] As shown in the figure, the battery cell 210 may include tabs or terminals 250, including a first tab or terminal 251 and an optional second tab or terminal 252. Each terminal 251, 252 may be electrically connected to a battery cell component within the housing 220. In some embodiments, each terminal 251, 252 is insulated from the cover 230.

[0051] In some embodiments, the battery cell 210 includes an electrode assembly 240. As shown in the figure, the electrode assembly 240 is indicated by dashed lines, signifying it as a component of the prismatic battery cell 210 within the rigid casing 220 (i.e., within the internal space 225). The electrode assembly 240 is shown having a plurality of electrode pair layers 242 arranged such that the flat surfaces of the electrode pair layers 242 are perpendicular to the short face 222. The electrode assembly 240 may be referred to as a stack 240 of electrode layers 242.

[0052] Figure 3 yes Figure 2 A cross-sectional schematic diagram of battery cell 210. In Figure 3 The image shows some of the internal components of the battery cell 210. Figure 4 yes Figure 3 A top view of battery cell 210.

[0053] like Figure 3 As shown, the battery cell 210 includes a conductive first structure 211 and a conductive second structure 212. Each structure 211, 212 is connected to... Figure 2 The electrode assembly 240 is electrically connected. Structures 211 and 212 can be referred to as welding plates.

[0054] In some embodiments, structure 211 may be a cathode plate, and structure 212 may be an anode plate. Alternatively, structure 211 may be an anode plate, and structure 212 may be a cathode plate. Structures 211 and 212 may be aluminum or copper. For example, the anode plate may be copper, and the cathode plate may be aluminum.

[0055] Structure 211 may be electrically connected to conductive rivet or connector 261, and structure 212 may be electrically connected to conductive rivet or connector 262. For example, as shown, structure 211 may be adjacent to conductive rivet or connector 261, and structure 212 may be adjacent to conductive rivet or connector 262.

[0056] like Figure 3 As shown, the cover 230 has a top side 232 and a bottom side 231. Furthermore, the cover 230 may be formed with an opening 235 extending from the top side 232 to the bottom side 231. Additionally, each connector 261, 262 may extend through a corresponding opening 235 and reach a distal end 265 through the cover 230. As shown, each connector 261, 262 extends in the direction indicated by arrow 99.

[0057] Figure 3 The diagram also shows that the battery cell 210 is provided with an insulating spacer or sleeve 270 located in each opening 235. The insulating sleeve 270 insulates the cover 230 from each corresponding connector 261, 262.

[0058] Cross-reference Figure 3 and Figure 4 The distal end 265 of connector 261 is electrically connected to terminal 251, and the distal end 265 of connector 262 is electrically connected to terminal 252. Battery cell 210 is provided with an insulating plate 280 located above cover 230. The insulating plate 280 insulates cover 230 from each corresponding terminal 251, 252. The insulating plate 280 may be ceramic.

[0059] like Figure 3 As shown, an insulating insert 290 is provided between the cover 230 and structures 211, 212. In some embodiments, the insert 290 is formed of a thermoplastic resin. For example, the insert 290 may be made of polypropylene.

[0060] like Figure 3 As shown, insert 290 contacts the bottom side 231 of cover 230. Insert 290 also contacts cathode / anode structures 211, 212, as also shown. In some embodiments, insert 290 is compressed between cover 230 and cathode / anode structures 211, 212. Insulating insert 290 can insulate housing 220 from structures 211 and 212, and can also insulate housing 220 from connectors 261 and 262. Specifically, insulating insert 290 can provide ohmic resistance between cover 230 and electrode assembly 240 and / or internal busing circuit.

[0061] exist Figure 3 In some embodiments, the insulating insert 290 may be a single piece. For example, the insert 290 may be formed of a thermoplastic resin. The insert 290 may be formed by injection molding.

[0062] exist Figure 3 In one embodiment, the insulating insert 290 has a bottom surface 298 that abuts against and directly contacts the structure 211. Additionally, region 291 has a top surface 299 that abuts against and directly contacts the cover 230 (and the insulating sleeve 270).

[0063] exist Figure 3 In this configuration, the insulating insert 290 is formed with an opening 295 and has an inner surface 296 defining the opening 295. As shown, connectors 261 and 262 extend through the opening 295 such that the inner surface 296 contacts connectors 261 and 262.

[0064] In some embodiments, the cover 230, insulating insert 290, sleeve 270, insulating plate 280, connectors 261 and 262, terminals 251, 252, and cathode and anode structures 211, 212 may be pre-assembled and provided as cover assembly 199.

[0065] During battery assembly, a pre-assembled cover assembly 199 can be positioned above an electrode foil 241 electrically connected to the electrode assembly 240 and / or to an internal bus circuit (electrically connected to the electrode assembly 240). Subsequently, cathode and anode structures 211, 212 can be coupled to one or more electrode foils 241 electrically connected to the electrode assembly 240 and / or to an internal bus circuit (electrically connected to the electrode assembly 240).

[0066] For example, welding processes (such as laser welding) can be used to electrically connect the cathode and anode structures 211, 212 to the electrode assembly 240, such as by connecting them to the electrode foil 241.

[0067] Figure 5 This is an end view of an embodiment of component 200, which facilitates the application of insulating tape 500 to structurally connect the stack 240 of electrode layers 242 to the cover assembly 199. Specifically, insulating tape 500 may be used to structurally connect the insulating insert 290 and the outer surface 247 of the stack 240 of electrode layers. In some embodiments, insulating tape 500 is polypropylene tape.

[0068] like Figure 5 As shown, the insulating insert 290 includes a laterally extending body 310. Specifically, the body 310 extends laterally between its outer lateral edges 311 and 312 in a direction substantially perpendicular to the vertical direction 99, as indicated by arrow 98. The body 310 may form a bottom surface 298 and a top surface 299 of the insulating insert 290. As shown, the bottom surface 298 and the top surface 299 may each be perpendicular to the vertical direction 99. Furthermore, the bottom surface 298 and the top surface may be spaced apart from each other by a body thickness or body length 399.

[0069] Furthermore, the insulating insert 290 includes legs 400 extending downward from the body 310 to the distal end or edge 410 in the direction of arrow 99. Each leg 400 may have a length 499 from the bottom surface 298 to the distal end 410. As shown, the downwardly extending legs 400 may form outer surfaces 421 and 422.

[0070] In some embodiments, outer surface 421 is continuous with outer lateral edge 311, and outer surface 422 is continuous with outer lateral edge 312. Therefore, the insulating insert 290 is formed with outer surface 239, the length of which is equal to the sum of lengths 399 and 499. In some embodiments, the length of each outer surface 239 is ten (10) to twelve (12) millimeters.

[0071] In the embodiments described herein, as shown, insulating tape 500 is adhered to the outer surfaces 421 and 422 of the legs 400 of the insulating insert 290, and to the outer surface 247 of the electrode layer stack 240. Insulating tape 500 may also be adhered to the outer lateral edges 311 and 312.

[0072] Figure 6 and Figure 7 The figure illustrates an embodiment of the insulating insert 290, wherein the leg 400 is pivotally mounted to the body 310 via a hinge 600. Figure 6 The diagram shows the insulating insert 290 in installation configuration 290', wherein, as mentioned above... Figure 5 As described, the support leg 400 extends downward from the main body 310.

[0073] exist Figure 7 In the middle, the outrigger 400 is pivoted outward to extend laterally in the non-installation configuration 290”.

[0074] exist Figure 6 and Figure 7 In this configuration, the main body 310 and the support leg 400 are separate components that are pivotally fixed together by a hinge 600 to provide movement of the support leg 400 between configurations 290' and 290".

[0075] Figure 8 and Figure 9 The figure illustrates an embodiment of the insulating insert 290, wherein the leg 400 is attachable to the body 310 via the connection feature 800 and is detachable. Figure 8 The diagram shows the insulating insert 290 in installation configuration 290', wherein, as mentioned above... Figure 5 As described, the support leg 400 is attached to the main body 310 and extends downward from the main body 310.

[0076] exist Figure 9 In the middle, the outrigger 400 is separated from the main body 310 in the non-installation configuration 290”.

[0077] exist Figure 8 and Figure 9In this configuration, the body 310 and the leg 400 are distinct components that can be selectively attached together or separated from each other by a connecting feature 800. As shown, the connecting feature 800 can be formed on the outer lateral edges 311 and 312 of the body 310 and can be received in or cooperate with a mating feature 810 formed on the leg 400. Alternatively, the connecting feature 800 can be formed on the leg 400, and the mating feature 810 can be formed on the body 310. In either case, the connecting feature 800 and the mating feature 810 provide selective engagement of the leg 400 to the body 310 to form an insulating insert 290 with a mounting configuration 290' when needed.

[0078] Figure 10 The figure illustrates an embodiment in which the main body 310 and the support leg 400 are integral. Furthermore, the support legs 400 are interconnected via end walls 490. As shown, the support legs 400 are fixed in a downwardly extending configuration.

[0079] Now for reference Figure 11 It provides a method 1100 for manufacturing or assembling batteries.

[0080] Method 1100 includes: at operation 1105, arranging a plurality of foils associated with a plurality of electrodes of a stacked battery cell.

[0081] Method 1100 includes: at operation 1115, positioning the cover assembly above a stack. In embodiments where the cover assembly has a non-mounted configuration and a mounted configuration, operation 1115 includes providing the cover assembly in the non-mounted configuration.

[0082] In some embodiments, method 1100 includes applying an insulating strip to the stacked battery cells at optional operation 1120 to hold the stacked battery cells together.

[0083] Method 1100 includes, at operation 1125, attaching battery cell tabs to a plurality of foils. For example, operation 1125 may include laser welding the battery cell tabs to the plurality of foils.

[0084] In some embodiments, method 1100 includes applying an insulating strip to the anode / cathode plate at optional operation 1130.

[0085] Method 1100 further includes, at operation 1135, moving the cover assembly (specifically, the insulating insert) from a non-mounting configuration to a mounting configuration. For example, operation 1135 may include pivoting the articulated leg from a laterally extending outward configuration to a downward extending configuration. Alternatively, operation 1135 may include attaching a previously separated leg to the body of the insulating insert.

[0086] In embodiments where the insulating insert has a single configuration, operation 1135 may not be performed.

[0087] Method 1100 further includes, at operation 1145, adhering insulating tape to the outer surface of the stack and the outer surface of the cover assembly, such as adhering to the legs of the insulating insert or the legs and body, to completely cover (i.e., encapsulate) the interface between the stack and the cover assembly.

[0088] Method 1100 may also include completing the encapsulation of the battery cell in the housing at operation 1155. For example, the battery cover may be sealed to the housing.

[0089] Although Figure 11 Operations 1105-1155 are shown in the described order, but method 1100 can be performed in any suitable order. For example, the legs can be moved from a non-mounting configuration to a mounting configuration before or after the battery cell tabs are attached to the foil. Additionally, the tape can be adhered to the stack and cover assembly before or after the battery cell tabs are attached to the foil.

[0090] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that numerous variations exist. It should also be understood that the exemplary embodiments or multiple exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of this disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing the exemplary embodiments or multiple exemplary embodiments. It should be understood that various changes can be made to the function and arrangement of the elements without departing from the scope of this disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A method for manufacturing a battery, comprising: Multiple foils are arranged to be associated with multiple electrodes of battery cells in a stack, wherein the stack has an outer surface; A cover assembly is positioned above the stack, wherein the cover assembly has an outer surface and wherein the cover assembly includes conductive terminals electrically connected to battery cell tabs, wherein an insulating plate is located between the battery cell tabs and the conductive terminals; Connect the battery cell tabs to the plurality of foils; as well as The insulating tape is adhered to the outer surface of the stack and the outer surface of the cover assembly.

2. The method of claim 1, wherein connecting the battery cell tabs to the plurality of foils comprises laser welding the battery cell tabs to the plurality of foils.

3. The method according to claim 1, wherein: A first direction is defined by the connection from the conductive terminal to the battery cell tab; The insulating plate includes a body extending between lateral edges in a second direction perpendicular to the first direction; The insulating plate also includes legs extending from the lateral edge to the distal end; and The legs form the outer surface of the cover assembly.

4. The method of claim 3, wherein the leg is pivotally connected to the body via a hinge, and wherein the method includes moving the leg from an outwardly extending configuration to a downwardly extending configuration before adhering the insulating tape to the outer surface of the stack and the outer surface of the cover assembly.

5. The method of claim 3, further comprising attaching the legs to the body before adhering the insulating tape to the outer surfaces of the stack and the outer surfaces of the cover assembly.

6. The method of claim 3, further comprising attaching the legs to the body after the battery cell tabs are attached to the plurality of foils and before the insulating tape is adhered to the outer surfaces of the stack and the outer surfaces of the cover assembly.

7. The method of claim 3, wherein the leg is integrally formed with the body and is fixed in a downwardly extending configuration.

8. A battery assembly, comprising: Multiple foils, the multiple foils being associated with multiple electrodes of a battery cell in a stack, wherein the stack has an outer surface; A cover assembly, the cover assembly being placed above the stack, wherein the cover assembly comprises: Battery cell tabs, which are electrically connected to the plurality of foils; Conductive terminals, which are electrically connected to the battery cell tabs; and An insulating plate, the insulating plate being located between the battery cell tab and the conductive terminal, wherein the insulating plate includes a laterally extending body and downwardly extending legs, and wherein the cover assembly has an outer surface formed by the legs; and Insulating tape is adhered to the outer surface of the stack and the outer surface of the cover assembly.

9. The battery assembly of claim 8, wherein the downwardly extending leg is hinged to the body.

10. The battery assembly of claim 8, wherein the downwardly extending leg is connected to the body via a friction fit.

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