Clamp-on battery connection

Abstract

Clamped battery connections are provided. Battery assemblies, vehicles having battery assemblies, and methods for manufacturing batteries are provided. A method for manufacturing a battery includes providing an electrode stack, where each electrode is electrically connected to a foil; clamping a first electrode foil with a first clamp; laser welding the first electrode foil to the first clamp; positioning a cover plate over the first clamp; and laser welding the cover plate to the first clamp.

Description

Technical Field

[0001] This disclosure generally relates to assembly strategies for batteries, and more specifically to batteries and methods that enable the electrode foil of an electrode stack to be clamped and welded before a cover assembly is positioned and welded over the electrode stack. Background Technology

[0002] Lithium-ion and related batteries are used in automotive and related transportation applications, either as a supplement to conventional internal combustion engines (ICE) in hybrid electric vehicles (HEVs) or as an alternative to conventional ICE in pure electric vehicles (EVs). The ability to passively store energy from stationary and portable sources, as well as recovered kinetic energy from the vehicle and its components, makes these 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 module and group components 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 sheets, to generate current flow. These electrode sheets contain extensions, i.e., foils, that extend outwards and are used to attach the electrode sheets 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.

[0004] There is a need for apparatus and methods for manufacturing or assembling batteries that provide an electrical connection to foils, improve the weld porosity, thermal conductivity, electrical conductivity, and tensile strength of the foils, and ensure that all foils are collected and connected. Furthermore, other desirable features and characteristics of this disclosure will become apparent from the following detailed description and appended claims, taken in conjunction with the accompanying drawings and the foregoing technical and background information. Summary of the Invention

[0005] In one embodiment, a method for manufacturing a battery is provided, and the method includes: providing an electrode stack, wherein each electrode is electrically connected to a foil; clamping a first electrode foil with a first fixture; laser welding the first electrode foil to the first fixture; positioning a cover plate above the first fixture; and laser welding the cover plate to the first fixture.

[0006] In some embodiments, the method further includes: holding a second electrode foil with a second clamp; laser welding the second electrode foil to the second clamp; and laser welding a cover plate to the second clamp.

[0007] In some embodiments, the method further includes: after clamping the first electrode foil with the first clamp, trimming excess areas of the first electrode foil not clamped by the first clamp; and after clamping the second electrode foil with the second clamp, trimming excess areas of the second electrode foil not clamped by the second clamp.

[0008] In some embodiments of the method, the cover plate includes a first terminal electrically connected to a first internal terminal board and a second terminal electrically connected to a second internal terminal board; laser welding the cover plate to a first fixture includes laser welding the first internal terminal board to the first fixture; and laser welding the cover plate to a second fixture includes laser welding the second internal terminal board to the second fixture.

[0009] In some embodiments of the method, the first clamp includes first and second lateral legs; clamping the first electrode foil with the first clamp includes reducing the gap between the first and second lateral legs; the second clamp includes first and second lateral legs; and clamping the second electrode foil with the second clamp includes reducing the gap between the first and second lateral legs.

[0010] In some embodiments of the method, for each clamp, reducing the gap between the first and second lateral legs includes moving at least one of the lateral legs in a first plane.

[0011] In some embodiments of the method, laser welding the first electrode foil to the first fixture includes welding along a first vertical interface perpendicular to the first plane; and laser welding the second electrode foil to the second fixture includes welding along a second vertical interface perpendicular to the first plane.

[0012] In some embodiments of the method, the first clamp includes a first vertical base member having a first inner surface perpendicular to the first plane and perpendicular to the first vertical interface; and the second clamp includes a second vertical base member having a second inner surface perpendicular to the first plane and perpendicular to the second vertical interface.

[0013] In some embodiments of the method, laser welding the cover plate to the first fixture includes welding along the first inner surface; and laser welding the cover plate to the second fixture includes welding along the second inner surface.

[0014] In some embodiments of the method, the cover plate includes a first terminal electrically connected to a first internal terminal board; laser welding the cover plate to a first fixture includes laser welding the first internal terminal board to the first fixture; the first fixture includes first and second lateral legs; clamping the first electrode foil with the first fixture includes reducing the gap between the first and second lateral legs by moving at least one of the lateral legs in a first plane; laser welding the first electrode foil to the first fixture includes welding along a first vertical interface perpendicular to the first plane; the first fixture includes a first vertical base member having a first inner surface perpendicular to the first plane and perpendicular to the first vertical interface; and laser welding the cover plate to the first fixture includes welding along the first inner surface.

[0015] In another embodiment, a battery assembly is provided, comprising: a first foil associated with a first electrode of a battery cell in a stack; a first clamp having a first lateral leg and a second lateral leg and a vertical base member having a first inner surface, wherein the first foil is located between the first lateral leg and the second lateral leg and is welded to the first lateral leg and the second lateral leg; and a cover plate located above the first lateral leg and the second lateral leg and having a first outer surface, wherein the first outer surface is welded to the first inner surface.

[0016] In some embodiments of the battery assembly, the cover includes a first terminal electrically connected to a first terminal plate, and a first outer surface is formed by the first terminal plate.

[0017] In some embodiments of the battery assembly, the first foil is welded to the first lateral leg and the second lateral leg via a first solder pool extending in the first vertical direction and the first lateral direction; and the first outer surface is welded to the first inner surface via a second solder pool extending in the first vertical direction and the second lateral direction perpendicular to the first lateral direction.

[0018] In some embodiments of the battery assembly, a first lateral support leg and a second lateral support leg define a first interface extending in a first vertical direction and a first lateral direction; and a first outer surface and a first inner surface define a second interface extending in a first vertical direction and a second lateral direction perpendicular to the first lateral direction.

[0019] In some embodiments, the battery assembly further includes: a second foil associated with a second electrode of a battery cell in the stack; and a second clamp having a first lateral leg and a second lateral leg and a vertical base member having a second inner surface, wherein the second foil is located between the first lateral leg and the second lateral leg and is welded to the first lateral leg and the second lateral leg; wherein the cover plate has a second outer surface and wherein the second outer surface is welded to the second inner surface.

[0020] In another embodiment, a vehicle is provided, and the vehicle includes: an electric motor configured to provide power torque; and a battery system operatively connected to and operable to provide power to the electric motor, wherein the battery system includes: a first foil associated with a first electrode of a battery cell in a stack; a first clamp having a first lateral leg and a second lateral leg and a vertical base member having a first inner surface, wherein the first foil is located between the first lateral leg and the second lateral leg and is welded to the first lateral leg and the second lateral leg; and a cover plate located above the first lateral leg and the second lateral leg and having a first outer surface, wherein the first outer surface is welded to the first inner surface.

[0021] In some embodiments of the vehicle, the cover includes a first terminal electrically connected to a first terminal plate, and a first outer surface is formed by the first terminal plate.

[0022] In some embodiments of the vehicle, the first foil is welded to the first lateral support leg and the second lateral support leg by a first weld pool extending in the first vertical direction and the first lateral direction; and the first outer surface is welded to the first inner surface by a second weld pool extending in the first vertical direction and the second lateral direction perpendicular to the first lateral direction.

[0023] In some embodiments of the vehicle, a first lateral outrigger and a second lateral outrigger are defined at a first interface extending in a first vertical direction and a first lateral direction; and a first outer surface and a first inner surface are defined at a second interface extending in a first vertical direction and a second lateral direction perpendicular to the first lateral direction.

[0024] In some embodiments of the vehicle, the battery system further includes: a second foil associated with a second electrode of a battery cell in a stack; and a second clamp having a first lateral leg and a second lateral leg and a vertical base member having a second inner surface, wherein the second foil is located between the first lateral leg and the second lateral leg and is welded to the first lateral leg and the second lateral leg, wherein a cover plate has a second outer surface and wherein the second outer surface is welded to the second inner surface. Attached Figure Description

[0025] The present disclosure will be described below with reference to the following figures, wherein the same numerals denote the same elements, and wherein:

[0026] Figure 1 This is a schematic perspective view of an electric vehicle according to an exemplary embodiment, having a cut-out portion to expose the battery housed in a battery casing.

[0027] Figure 2 This is according to an exemplary embodiment. Figure 1 A perspective view of the battery.

[0028] Figure 3 This is a flowchart illustrating a method for manufacturing and assembling a battery according to certain embodiments.

[0029] Figure 4 This illustrates certain embodiments of the invention. Figure 3 A perspective view of an electrode stack with electrode foil during the manufacturing stage of the method.

[0030] Figure 5 This illustrates certain embodiments of the invention. Figure 3 Clamping during subsequent manufacturing stages of the method Figure 4 A perspective view of the clamp for the electrode foil.

[0031] Figure 6 It is in the initial open configuration according to certain embodiments. Figure 5 A top view of the fixture.

[0032] Figure 7 It is in a clamping-open configuration according to certain embodiments. Figure 5 A top view of the fixture.

[0033] Figure 8 This illustrates certain embodiments of the invention. Figure 3 A perspective view of the fixtures that are welded to the electrode foil during the subsequent manufacturing stages of the method.

[0034] Figure 9 This illustrates certain embodiments of the invention. Figure 3A side view of the cover plate assembly located above the fixture and welded to the fixture during the subsequent manufacturing stage of the method.

[0035] Figure 10 According to certain embodiments, in relation to Figure 9 An end view of the cover plate assembly located above and welded to the fixture during the same manufacturing stage.

[0036] Figure 11 This is an end view schematic diagram of a battery after the cover has been sealed to the housing during a subsequent manufacturing stage, according to certain embodiments.

[0037] Figure 12 This illustrates, according to certain embodiments, in relation to Figure 5 A top view diagram showing the use of multiple fixtures for each type of electrode foil during the same manufacturing stage. Detailed Implementation

[0038] 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.

[0039] 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 contained 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.

[0040] 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,” “largely,” “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 for the purpose of performing the specified function.

[0041] The embodiments described herein provide a method for connecting electrode stacks and battery cover assemblies via a first laser-welded connection between the electrode foil and a fixture, and a second laser-welded connection between the fixture and a cover assembly. The embodiments described herein integrate a sandwich strategy for P-type batteries with electrode foils on the same side. The embodiments described herein improve the weld porosity, thermal conductivity, electrical conductivity, and tensile strength of the foils, and ensure that all foils are collected and connected.

[0042] The embodiments described herein provide novel foil-to-cover plate assemblies. In some embodiments, the integration of the interlayer welding design for the P-type foil with the cover plate assembly utilizes a horizontal laser welding strategy. The interlayer welding concept improves thermal conductivity, electrical conductivity, mechanical strength, and gathers all foils for the connection.

[0043] In some embodiments, a method includes: placing an anode foil between anode clamps and a cathode foil between cathode clamps; compressing the forks or legs of the clamps to press the foil together on both the anode and cathode sides; trimming any unclamped excess portion of the foil; welding the foil to the clamps; aligning each internal terminal block of the cover plate assembly with a corresponding clamp; and laser welding the clamps to the corresponding internal terminal blocks.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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 100.

[0048] 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.

[0049] In an exemplary embodiment, the battery module 200 is an assembly of battery cells.

[0050] Figure 2 The perspective view is shown schematically. Figure 1 The battery module 200. Specifically, Figure 2 The battery module 200 is shown as a prismatic battery 200.

[0051] The prismatic battery 200 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.

[0052] As shown in the figure, the housing 220 may be formed with an open end, which is covered or closed by a cover plate 230. In some embodiments, the cover plate 230 may be part of the housing 220. In some embodiments, the cover plate 230 is conductive. For example, the cover plate 230 may be metallic, such as aluminum or an aluminum alloy.

[0053] As shown in the figure, the battery 200 may include terminals 250, including a first terminal 251 and an optional second 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 plate 230.

[0054] In some embodiments, the battery 200 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 200 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.

[0055] Figure 3 This illustrates various aspects of the manufacture or assembly of batteries (such as...) according to this disclosure. Figure 2 The flowchart of method 300 for battery 200.

[0056] Figure 3 It is a combination Figures 4-11 To describe, Figures 4-11 The illustration shows a battery 200 or components of battery 200 at various assembly or manufacturing stages according to certain embodiments of the present disclosure of method 300. Method 300 is merely an example and is not intended to limit the present disclosure beyond what is expressly stated in the claims. Additional steps may be provided before, during, and after method 300, and for additional embodiments of method 300, certain steps described may be moved, replaced, or eliminated. Additional features may be added to the battery depicted in the figures, and in other embodiments of the battery, certain features described below may be replaced, modified, or eliminated.

[0057] At operation 310, method 300 provides an electrode stack, namely electrode assembly 240, such as Figure 4 As shown. Figure 4 This is a schematic perspective view of the internal components of the battery 200 during assembly; that is, the housing 220 and cover 230 are not shown. Figure 4 In the figure, electrode assemblies are typically indicated by reference numeral 240.

[0058] As shown in the figure, electrode assembly 240 is electrically connected to conductive foil 400. Specifically, the electrode assembly contains first and second electrodes, such as an anode and a cathode. Each first electrode is electrically connected to a first foil 401, and each second electrode is electrically connected to a second foil 402. As shown, the first foil 401 is spaced apart from the second foil 402 in the Y direction. The first foil 401 and the second foil 402 are further spaced apart from each other in the X direction, but... Figure 4 They are gathered together. Although in Figure 4 In this embodiment, the first foil 401 and the second foil are located above the same top surface 241 of the electrode assembly 240, but the embodiments herein are not limited to this configuration.

[0059] In some embodiments, one of the first foil 401 and the second foil 402 is aluminum, and the other of the first foil and the second foil is copper. Alternatively, other suitable materials may be used to form the first foil 401 and the second foil 402.

[0060] Method 300 continues at operation 315, that is, using the corresponding clamp 500 to clamp the first electrode foil and the second electrode foil, such as... Figure 5 As shown. For example, a first clamp 501 is used to clamp a first foil 401, and a second clamp 502 is used to clamp a second foil 402. Figure 5 In the middle, the clamp 500 is in the clamping configuration.

[0061] Figure 6 and Figure 7 This is a schematic top view of a representative fixture 500, in which... Figure 6 The initial open configuration is shown, and Figure 7 The clamping configuration is shown. Figure 7 The image shows a portion of foil 400, which is held by clamp 500.

[0062] Cross-reference Figures 5-7 Each fixture 500 includes a base member 510. The base member 510 may be L-shaped. Specifically, the base member 510 may have an L-shaped first end surface 516 and an L-shaped second end surface 517, and extend longitudinally (i.e., in the X direction) between the end surfaces 516 and 517.

[0063] As shown in the figure, the base member 510 may include an outer portion 520 and an inner portion 530. The outer portion 520 and the inner portion 530 share a common bottom surface 514 (facing...). Figure 5 (Electrode stacking in the middle). Furthermore, the base member 510 extends vertically upward (i.e., in the Z direction) from the bottom surface 514. Specifically, the outer portion 520 extends vertically upward to the upper surface 525, and the inner portion 530 extends upward to the upper surface 535. The outer portion 520 includes an outer surface 528 and an inner surface 529. The inner portion 530 includes an inner surface 539.

[0064] The base member 510 may have an internal vertical height and an external vertical height, the internal vertical height being defined as the vertical distance between the bottom surface 514 and the upper surface 535, and the external vertical height being defined as the vertical distance between the bottom surface 514 and the upper surface 525.

[0065] Still cross-reference Figures 5-7 Each clamp 500 also includes a support leg 550. Figure 5 and Figure 7 In the clamping configuration, the legs 550 extend laterally, that is, in the Y direction, and can be parallel to each other. Figure 6 In the initial open configuration, the outriggers 550 can be separated from each other.

[0066] like Figures 5-7 As shown, each leg 550 has a proximal end 551, which is mounted to or integral with the corresponding base member 510. Furthermore, each leg 550 extends from the corresponding base member 510 to a distal end 552. As shown, each leg has a bottom surface 553, a top surface 554, an outer surface 555, and an inner surface 556.

[0067] Each leg 550 may have a vertical height, which is defined as the distance from the bottom surface 553 to the top surface 554. In some embodiments, the vertical height of each leg 550 is equal to the internal vertical height of the base member 510.

[0068] During operation 315, each clamp 500 is positioned around the corresponding foil 400. Specifically, the foil 400 is received in a gap 560 between the inner surfaces 556 of the legs 550. Subsequently, the gap 560 is reduced, such as by pushing one or both legs 550 toward each other. Such movement occurs in the XY plane.

[0069] As a result, the foil 400 is compressed between the inner surfaces 556 of the corresponding legs 550. For example... Figure 7 As shown, foil 400 contacts inner surface 556 at interface 559. Inner surface 556 and interface 559 can be vertical, such as coplanar with the YZ plane. Figure 5 As shown, the excess end portion 499 extends above and away from the clamp 500.

[0070] In some embodiments, a first clamp 501 clamps a first foil 401, and the first clamp 501 and the first foil 401 are made of the same material; and a second clamp 502 clamps a second foil 402, and the second clamp 502 and the second foil 402 are made of the same material. In some embodiments, the first foil 401 and the first clamp 501 may be one of copper and aluminum, and the second foil 402 and the second clamp 502 may be the other of copper and aluminum.

[0071] Method 300 can continue at operation 320, that is, trimming the excess foil 499 that is not clamped by fixture 500, such as... Figure 8 As shown.

[0072] Still referencing Figure 8 Method 300 can continue at operation 325, whereby the electrode foil 400 is laser welded to the corresponding fixture 500. For example, laser welding can be performed along one or more vertical interfaces 559 perpendicular to the XY plane (i.e., in the YZ plane 599).

[0073] During laser welding, the heated portion of each foil 400 can melt, and the heated portion of the fixture 500 at interface 559 can also melt. After the laser passes, the molten portions solidify and fuse to form a weld nugget 600, such as along the vertical interface 559. When melting, the molten portion can travel downwards in the Z direction under the influence of gravity. Therefore, the weld nugget can extend to a depth below the deepest focal point of the laser.

[0074] When the foil 400 is pressed between the opposing inner surfaces 556 of the respective legs 550, the solder nugget is formed along one or more vertical YZ planes defined and located therebetween by the opposing inner surfaces 556 of the respective legs 550. An exemplary vertical YZ plane is indicated by reference numeral 599.

[0075] After welding foil 400 and corresponding fixture 500, each welded structure can be referred to as an internal weld plate. In other words, the first foil 401 and the first fixture 501 form a first internal weld plate, and the second foil 402 and the second fixture 502 form a second internal weld plate.

[0076] Method 300 can continue at operation 330, that is, positioning the cover plate assembly 700 above the fixture 500, such as... Figure 9 and Figure 10 As shown. Figure 9 A side view of the cover assembly 700 above the electrode stack 240 and the fixture 500 is provided, and Figure 10 An end view of the cover assembly 700 above the electrode stack 240 and the clamp 500 is provided.

[0077] Cross-reference Figure 9 and Figure 10 The cover assembly 700 includes a cover 230. Furthermore, the cover assembly 700 includes an isolation insert 720 on the underside of the cover 230. Both the cover 230 and the isolation insert 720 have openings (not shown). Additionally, the cover assembly 700 includes terminals 730, including a first terminal 731 and a second terminal 732. Furthermore, the cover assembly 700 includes an internal terminal plate 740, including a first internal terminal plate 741 and a second internal terminal plate 742.

[0078] Terminal 730 passes through cover plate 230 and isolation insert 720 and is electrically connected to internal terminal plate 740. Specifically, first terminal 731 is electrically connected to first internal terminal plate 741, and second terminal 732 is electrically connected to second internal terminal plate 742.

[0079] When the cover assembly 700 is positioned above the clamp 500, the internal terminal plate 740 is aligned with the clamp 500. Specifically, the first internal terminal plate 741 is aligned with the first clamp 501, and the second internal terminal plate 742 is aligned with the second clamp 502.

[0080] As shown in the figure, each internal terminal block 740 can be received within the outer portion 520 of the clamp 500 and is located directly above the inner portion 530 of the clamp 500. Each internal terminal block 740 may have an outer surface 745 that directly contacts the inner surface 529 of the outer portion 520, and may have a bottom surface 748 that directly contacts the upper surface 535 of the inner portion 530. Note that the outer portion 520 is... Figure 10 The middle section is partially transparent to allow observation of the position of the internal terminal block 740 on the internal portion 530.

[0081] Method 300 can continue at operation 335, which involves laser welding the cover plate assembly 700 to the fixture 500. Specifically, operation 335 may include laser welding the internal terminal board 740 to the fixture 500. For example, operation 335 includes performing a first process of laser welding a first internal terminal board 741 to a first fixture 501, and performing a second process of laser welding a second internal terminal board 742 to a second fixture 502.

[0082] Each welding process can be performed along a corresponding vertical interface 795 formed at or between the respective outer surface 745 and inner surface 529. For example, each vertical interface 795 can be coplanar with or parallel to the XZ plane.

[0083] During each laser welding process, the laser is focused at the visible interface 795 between the outer surface 745 and the inner surface 529, and can be moved from one end surface 516 to the other end surface 517. Heated portions of the fixture 500 and the internal terminal block 740 can melt. After the laser passes, the molten portions solidify and fuse to form a weld nugget 800, such as along the vertical interface 795. While melting, the molten portion can travel downwards in the Z direction under gravity. Therefore, the weld nugget can extend to a depth below the deepest focal point of the laser. The weld nugget is formed along one or more vertical XZ planes defined by and between the outer surface 745 and the inner surface 529. Exemplary vertical XZ planes are indicated by reference numeral 810. Each plane 810 is coplanar with or parallel to the XY plane.

[0084] As described, the laser welding process can be performed using a horizontally applied laser. Alternatively, the component can be rotated ninety degrees from the indicated orientation so that the laser is applied vertically (i.e., from top to bottom), and the interface 795 is horizontally oriented during the welding process.

[0085] Method 300 may also include positioning internal components of the battery 200 within the housing 220 at operation 340, such as Figure 11 The end diagram is shown. For example, cover 230 can be sealed to housing 220.

[0086] While the embodiments herein have described a single clamp for each type of electrode foil, namely a single first clamp 501 welded to all first foils 401 and a single second clamp 502 welded to all second foils 402, other embodiments are also contemplated.

[0087] For example, Figure 12 One embodiment is shown in which two first clamps 501 are clamped to two separate bundles or piles of first foil 401, and two second clamps 502 are clamped to two separate bundles or piles of second foil 402. Other arrangements may also be used.

[0088] 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, the method comprising: An electrode stack is provided, wherein each electrode is electrically connected to a foil; The first electrode foil is held in place by the first clamp; The first electrode foil is laser-welded to the first fixture; Position the cover plate above the first clamp; as well as The cover plate is laser welded to the first fixture.

2. The method according to claim 1, further comprising: The second electrode foil is held in place by the second clamp; Laser welding the second electrode foil to the second fixture; and The cover plate is laser welded to the second fixture.

3. The method according to claim 2, further comprising: After clamping the first electrode foil with the first clamp, trim any excess areas of the first electrode foil that were not clamped by the first clamp. as well as After clamping the second electrode foil with the second clamp, trim any excess areas of the second electrode foil that were not clamped by the second clamp.

4. The method according to claim 3, wherein: The cover plate includes a first terminal electrically connected to a first internal terminal block and a second terminal electrically connected to a second internal terminal block; Laser welding the cover plate to the first fixture includes laser welding the first internal terminal plate to the first fixture; and Laser welding the cover plate to the second fixture includes laser welding the second internal terminal board to the second fixture.

5. The method according to claim 4, wherein: The first clamp includes first and second lateral support legs; Clamping the first electrode foil with the first clamp includes reducing the gap between the first and second lateral legs; The second clamp includes first and second lateral legs; and Clamping the second electrode foil with the second clamp includes reducing the gap between the first and second lateral legs.

6. The method according to claim 5, wherein, For each clamp, reducing the gap between the first and second lateral legs includes moving at least one of the lateral legs in a first plane.

7. The method according to claim 6, wherein: Laser welding the first electrode foil to the first fixture includes welding along a first vertical interface perpendicular to the first plane; Laser welding the second electrode foil to the second fixture includes welding along a second vertical interface perpendicular to the first plane; The first clamp includes a first vertical base member, the first vertical base member having a first inner surface that is perpendicular to the first plane and perpendicular to the first vertical interface; The second clamp includes a second vertical base member having a second inner surface that is perpendicular to the first plane and perpendicular to the second vertical interface; Laser welding the cover plate to the first fixture includes welding along the first inner surface; and Laser welding the cover plate to the second fixture includes welding along the second inner surface.

8. The method according to claim 1, wherein: The cover plate includes a first terminal electrically connected to a first internal terminal block; Laser welding the cover plate to the first fixture includes laser welding the first internal terminal plate to the first fixture; The first clamp includes first and second lateral support legs; Clamping the first electrode foil with the first clamp includes reducing the gap between the first and second lateral legs by moving at least one of the lateral legs in a first plane; Laser welding the first electrode foil to the first fixture includes welding along a first vertical interface perpendicular to the first plane; The first clamp includes a first vertical base member, the first vertical base member having a first inner surface that is perpendicular to the first plane and perpendicular to the first vertical interface; as well as Laser welding the cover plate to the first fixture includes welding along the first inner surface.

9. A battery assembly, comprising: The first foil is associated with the first electrode of the battery cell in the stack; A first clamp having a first lateral leg and a second lateral leg, and a vertical base member having a first inner surface, wherein a first foil is located between the first lateral leg and the second lateral leg and is welded to the first lateral leg and the second lateral leg. as well as A cover plate located above the first lateral support leg and the second lateral support leg, and having a first outer surface, wherein the first outer surface is welded to the first inner surface.

10. The battery assembly of claim 9, wherein the cover includes a first terminal electrically connected to a first terminal plate, and wherein the first outer surface is formed by the first terminal plate.

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