Corrugated foil strips for battery cells

Abstract

Some of the embodiments disclosed herein relate to battery cells with corrugated foil strips. Some embodiments may comprise a battery cell comprising a cathode, an anode, and a corrugated foil strip connected to the cathode or the anode, wherein the corrugated foil strip has a length in a first plane, has alternating peaks and troughs along its length in a second plane, and has a width in a third plane, wherein the first plane, the second plane, and the third plane are orthogonal to each other. Other embodiments may be disclosed or claimed.

Description

INITIATIONThe subject disclosure relates to battery cells. In particular, the embodiments of the present disclosure relate to battery cells having corrugated foil strips.Batteries are increasingly used in a variety of systems, ranging from mobile computing devices to electric motor vehicles. Such batteries may have multiple cells, each cell including a cathode and an anode separated by a separator. Each cell generally comprises a foil strip extending from the cathode and a further foil strip extending from the anode, wherein a plurality of foil strips extending from the cathode and the anode of a plurality of electrodes are connected to a common connection strip.Among other things, embodiments of the present disclosure provide improved battery cell coupled tabs that help absorb shocks and vibrations and prevent undesirable failure modes, such as an increase in cell resistance, additional heat generation, and the production of undesirable byproducts that may result in thermal runaway of the battery.SUMMARYIn an exemplary embodiment, a battery is provided. The battery includes a cathode, an anode, and a corrugated foil strip connected to the cathode or the anode. The corrugated foil strip has a length in a first plane, includes alternating peaks and valleys in a second plane along the length of the corrugated foil strip, and has a width in a third plane. The first plane, the second plane, and the third plane are orthogonal to each other.In addition to one or more of the features described herein, the corrugated foil strip is a first corrugated foil strip connected to the cathode, the battery cell further comprising a second corrugated foil strip connected to the anode.In addition to one or more of the features described herein, the first corrugated foil strip is connected to the cathode at a first end of the first corrugated foil strip and to a first terminal strip at a second end of the first corrugated foil strip, wherein the first end of the first corrugated foil strip is opposite the second end of the first corrugated foil strip.In addition to one or more of the features described herein, the first corrugated foil strip includes an insulating coating at the first end of the first corrugated foil strip.In addition to one or more of the features described herein, the insulative coating comprises a polymer and a ceramic material.In addition to one or more of the features described herein, the insulative coating has a thickness of about 5 micrometers to 40 micrometers.In addition to one or more of the features described herein, the first corrugated foil strip includes a polymer coating on the second end of the first corrugated foil strip, the polymer coating including one or more of a thermoplastic, polytetrafluoroethylene (PTFE), polyvinyl chloride (PVC), polyurethane, acrylonitrile butadiene rubber (NBR), a polytetrafluoroethylene / butyl rubber blend, a nylon-6 / polypropylene blend, and an interpenetrating urethane / acrylate polymer network.In addition to one or more of the features described herein, the polymeric coating on the second end of the first corrugated foil strip has a thickness of about one micrometer and two micrometers.In addition to one or more of the features described herein, the second corrugated foil strip is connected to the anode at a first end of the second corrugated foil strip and to a second terminal strip at a second end of the second corrugated foil strip, wherein the first end of the second corrugated foil strip is opposite the second end of the second corrugated foil strip.In addition to one or more of the features described herein, the corrugated foil strip includes copper and at least one of: about one to two mass percent tin, about 0.1 to 0.2 mass percent zinc, and about 0.2 to 0.5 mass percent magnesium.In addition to one or more of the features described herein, the corrugated foil strip comprises aluminum and at least one of: about 0.1 to 0.4 mass percent iron and about 0.1 to 0.5 mass percent silicon.In addition to one or more of the features described herein, the battery cell has a pouch cell shape, a prismatic cell shape, or a cylindrical cell shape.In addition to one or more of the features described herein, the battery cell has a prismatic cell shape, and the corrugated foil strip is directly connected to the cathode or the anode without an intervening interconnect structure.In addition to one or more of the features described herein, the battery cell has a prismatic cell shape, and wherein the corrugated foil strip is connected to the cathode or the anode via a non-corrugated strip extending from the cathode or the anode.In addition to one or more of the features described herein, the battery has a cylindrical cell shape in which the corrugated foil strip is directly connected to the cathode or the anode without an intervening interconnect structure.In addition to one or more of the features described herein, the battery cell has a cylindrical cell shape, wherein the corrugated foil strip is connected to the cathode or the anode at a first end of the corrugated foil strip, wherein the corrugated foil strip is connected to a cap of the cylindrical cell at a second end of the corrugated foil strip, and wherein the first end of the corrugated foil strip is opposite the second end of the corrugated foil strip.In addition to one or more of the features described herein, the peaks and valleys of the corrugated foil strip have an angular cross-section in the second plane, a trapezoidal cross-section in the second plane, or a combination of angular and trapezoidal cross-sections in the second plane.In addition to one or more of the features described herein, the peaks and valleys of the corrugated foil strip have a symmetric cross-section in the second plane or an asymmetric cross-section in the second plane.In another exemplary embodiment, a system is provided. The system includes a battery cell including a cathode, an anode, and an undulated foil strip connected to the cathode or the anode. The corrugated foil strip has a length in a first plane, includes alternating peaks and valleys in a second plane along the length of the corrugated foil strip, and has a width in a third plane. The first plane, the second plane, and the third plane are orthogonal to each other.In another exemplary embodiment, a vehicle is provided. The vehicle includes an electric motor and a battery pack coupled to the electric motor, the battery pack including a battery cell. The battery cell includes a cathode, an anode, and a corrugated foil strip connected to the cathode or the anode. The corrugated foil strip has a length in a first plane, includes alternating peaks and valleys in a second plane along the length of the corrugated foil strip, and has a width in a third plane. The first plane, the second plane, and the third plane are orthogonal to each other.The foregoing features and advantages, as well as other features and advantages of the disclosure, will be readily apparent from the following detailed description when taken in conjunction with the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGSOther features, advantages and details are included, by way of example only, in the following detailed description, which relates to the drawings, in which: FIG. 1 is a diagram of a vehicle for use in connection with one or more embodiments of the present disclosure; FIG. 2A is a diagram illustrating a side view of an example electrode stack in a battery cell according to embodiments of the present disclosure; FIG. 2B is a diagram illustrating an isometric view of the example electrode stack in FIG. 2A, in accordance with embodiments of the present disclosure; FIG. 2C is a diagram illustrating an example of joining foil strips to a battery cell according to embodiments of the present disclosure; FIG. 2D is a diagram illustrating another example of joining foil strips to a battery cell according to embodiments of the present disclosure; FIG. 3A is a diagram illustrating the connection of foil strips to a connection strip according to embodiments of the present disclosure; FIG. 3B is a diagram illustrating another view of the connection of foil strips to a connection strip in FIG. 3A according to embodiments of the present disclosure; FIG. 4 illustrates diagrams of example prismatic battery cell configurations, according to various embodiments; FIG. 5A is a diagram of a configuration of a cylindrical battery cell according to various embodiments; FIG. 5B is a diagram of another configuration of a cylindrical battery cell according to various embodiments; FIG. 6 is a side view of an alternative embodiment of a corrugated foil strip in accordance with the present disclosure; and FIG. 7 illustrates an example of the dimensions and geometry of a corrugated foil strip according to various embodiments.DETAILED DESCRIPTIONThe following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or use. It is understood that the same or corresponding parts and features are denoted by corresponding reference numerals in the drawings.According to an exemplary embodiment, a battery cell with improved foil strips is provided. In some embodiments, corrugated foil strips may be attached to the cathode, anode, or both the cathode and anode of an electrode stack or a jelly roll for a battery cell to achieve improved flexibility and strain relief in the strip so that the strips do not tear during manufacturing or operation during impacts. In some embodiments, the corrugated foil strips may include a polymeric coating that contributes to further damping to further reduce shocks and vibrations. In this way, embodiments of the present disclosure provide more robust and durable battery cells that are less susceptible to failures caused by torn or damaged strips, including an increase in cell resistance, additional heat buildup, and the formation of byproducts from the electrolyte of the cell. In some embodiments, corrugated terminal strips may be connected to the corrugated foil strips of the cathode, anode, or both the cathode and anode of a battery cell electrode stack to provide further flexibility and strain relief in the strip. This prevents the strips from breaking due to impacts during manufacture or operation.FIG. 1 illustrates a diagram of a vehicle 100 for use in connection with one or more embodiments of the present disclosure. The vehicle 100 includes a charge port 102, a battery 104, and an electric motor 106. In one embodiment, the vehicle 100 is a hybrid vehicle that uses both an internal combustion engine and an electric motor. In another embodiment, the vehicle 100 is an electric vehicle that is powered solely by electric motors. In example embodiments, the vehicle 100 is configured to be connected via the charging port 102 to a high voltage power source (i.e., a voltage source of at least 200 volts (V)) used to charge the battery 104. The electric motor 106 is configured to receive power from the battery 104 to provide propulsion of the vehicle 100.FIG. 2A is a diagram illustrating a side view of an exemplary battery cell stack according to embodiments of the present disclosure. In this example, a battery cell 200 includes a plurality of two cells, each two cell including an anode / cathode pair. A two-cell 210 consists, for example, of an anode 220 and a cathode 230. Each anode and cathode has active material coatings on the foil films used as current collectors. The foil strips are not coated with active material and are each disposed on one side of the anode and the cathode. The film strips are produced by a release process. Each anode and cathode in the battery cell 200 has a corresponding corrugated portion, which may be part of a unitary extension of an existing foil strip, or (alternatively), the existing foil strip of the cell may be connected to a separate and extended corrugated foil strip. For example, in the two-cell 210, the anode 220 has a uniform extension of the corrugated foil strip 222 and the cathode 230 has a uniform extension of the corrugated foil strip 232. Anode 220 and cathode 230 are further separated from each other by insulating layers 240. FIG. 2B shows an isometric view of the battery cell 200 and the dual cell 210.As shown in FIG. 2A, the corrugated foil strip 232 connected to the cathode 230 includes an insulated coated portion 234 near the edge of the cathode 230 to avoid contact (and thus short circuit) between the anode 220 and the cathode 230. In this example, the cathode 230 is smaller in all dimensions than the anode 220. In this example, there is no corresponding insulating layer on the corrugated foil strip 222 connected to the anode edge. In some embodiments, the isolated portion 234 may be part of a unitary structure of the strip 232 without intervening interconnect structures. Alternatively, the insulated portion 234 may be a separate structure that is joined to the strip 232 (e.g., by welding or riveting).As shown in FIGS. 2A and 2B, the corrugated foil strips 222, 232 may have a length in a first plane (e.g., x-plane) with alternating peaks and valleys in a second plane (e.g., y-plane) and a width in a third plane (e.g., z-plane), where the first, second, and third planes are orthogonal to each other in a three-dimensional configuration. The corrugated foil strips 222, 232 may be of any suitable dimensions to provide sufficient mechanical strength and to conduct current from the battery two-cell 210. In some embodiments, the corrugated foil strips 222, 232 have a thickness in the range of about 5 μm to 200 μm, for example.The insulating layer on portion 234 may include a polymer (e.g., polyvinylidene fluoride or PVDF) binder and a ceramic (e.g., alumina powder 10~50 wt % and / or rare earth oxide 0.1~3 wt %). In some embodiments, the insulating coating in portion 234 may have a width of about 2.0-6.0 mm and a thickness of about 5-40 μm.In some embodiments, the corrugated foil strips 222 may comprise copper (e.g., with 99.9 wt % copper and 0.1 wt % phosphorus). In some embodiments, the corrugated foil strips 232 may comprise aluminum (e.g., 99.0-99.95 wt % aluminum and 0.05-0.20 wt % copper). In some embodiments, the corrugated foil strips 222 and 232 may comprise copper or aluminum alloys. Copper alloys may include, for example, copper and one or more of the following (in mass percent): 1.0-2.0 Sn, 0.1-0.2 Zn, 0.2-0.5 Mg. In another example, aluminum alloys may comprise aluminum and one or more of the following constituents in mass percent: 0.1-0.4 Fe, 0.1-0.5 Si. In some embodiments, the corrugated foil strips of the present disclosure may comprise C110 (99.9% Cu). In some embodiments, the corrugated foil strips of the present disclosure may include Al 1100 (99-99.95% Al, Cu 0.2-0.6%, Fe≤0.4%, Mn≤0.15%, Si≤0.4%, Ti≤0.15%).Corrugated foil strips may be connected to the cathodes and anodes of a battery cell in connection with embodiments of the present disclosure in a variety of configurations. Corrugated foils may be combined into one or more groups. For example, FIG. 2C is a diagram illustrating an example of joining foil strips to a battery cell according to embodiments of the present disclosure. In this example, the battery cell 250 includes a plurality of cathodes connected to individual corrugated foil strips. The battery cell 250 has a corresponding corrugated portion, which may be part of a unitary extension of an existing foil strip, or the existing foil strip of the cell may be connected to a separate and extended corrugated foil strip. For example, corrugated foil strip 232 ais a unitary extension of the foil strips of cathode 230 a, cathode 230 band cathode 230 cat a first end and terminal strip 238 at a second end (the first and second ends are opposite each other). The existing foil strips of cathode 230a, cathode 230b and cathode 230c may be corrugated at once. An advantage of the embodiment in Fig. 2C is intended to simplify the construction of the corrugated strips by reducing the total number of foil strip layers for corrugation. Moreover, in some embodiments, some foil strips may be corrugated and others may not be corrugated, e.g., to provide corrugated strips in portions of the battery cell that tend to be subjected to a higher stress than other portions of the battery.FIG. 2D is a diagram illustrating another example of terminal foil strips of a battery cell 260 according to embodiments of the present disclosure. In this example, the co-corrugated foil strip 262 is a unitary extension of a plurality of all of the cathode foil strips and is in turn connected to the terminal strip 238. This configuration may, among other things, help improve efficiency in the manufacture of battery cells according to embodiments of the present disclosure by minimizing the corrugation of the tab 262.FIG. 3A is a diagram illustrating the connection of foil strips to a connection strip according to embodiments of the present disclosure. In this example, the diagram 300 illustrates portions of the corrugated foil strips 305 (e.g., the corrugated foil strips 222, 232 of FIG. 2A ) having a polymer coated surface 310 and an uncoated surface 320. Also shown is a terminal strip 330. The film strips 305 are combined at 340 such that the uncoated surface 320 is bonded to the terminal strip 330 (see illustration). In some embodiments, the terminal strip connected to a corrugated foil strip (e.g., terminal strip 330) may also be corrugated and / or have a coated and uncoated portion.FIG. 3B is a diagram 350 illustrating another view of the connection of foil strips to a connection strip in FIG. 3A, in accordance with embodiments of the present disclosure. In this example, the positioning of the leader 330 relative to the weld zone 360 is illustrated.The coating on portion 310 shown in the examples of FIGS. 3A and 3B may act as a damper to eliminate or reduce vibrational energy due to friction. In some embodiments, the coating material may comprise polymers (e.g., thermoplastics) or polymer composites. Examples of polymers that may be used on the coated surface 310 include polytetrafluoroethylene (PTFE), polyvinyl chloride (PVC), polyurethane, acrylonitrile butadiene rubber (NBR), a polytetrafluoroethylene / butyl rubber blend, a nylon 6 / polypropylene blend, and an interpenetrating urethane / acrylate polymer network.In some embodiments, the coated surface 310 may comprise an elastomer or other amorphous thermoplastic having a glass transition temperature below room temperature. In some embodiments, the coated surface may comprise a polymer blend or an interpenetrating network. In one embodiment, the coating material may comprise, for example, a polymer composition of 50:50 or 30:70 polyvinyl chloride (PVC) and acrylonitrile butadiene rubber (NBR). In some embodiments, the coating material on the coated surface 310 may have a thickness in the range of about 1-2 μm. As shown in FIGS. 3A and 3B, the coated surface 310 may begin at the edge of the electrode and end at the edge of the stripe weld zone 360. This contributes, inter alia, to the fact that the coating does not prevent the welding of the foil strips 305 to the connection strip 330.The corrugated foil strips described herein may be used in connection with a variety of different battery cell shapes. For example, FIG. 4 is a diagram of a configuration of a prismatic battery cell according to various embodiments. In this example, the battery cell 400 includes corrugated foil strips 222, 232 that may be unitary structures, extend from the anodes and cathodes, or are connected to the anodes and cathodes, respectively, of the battery cell 400. The battery cell 400 is, in this example, a "jelly roll" structure 407 enclosed by a can 405. In this example, the jelly roll 407 is a flat wound jelly roll structure, but embodiments of the present disclosure may function in conjunction with a stacked jelly roll structure or other suitable battery configuration. The insulating layer 420 separates the corrugated foil strips 222, 232 to prevent short circuit, and the corrugated foil strips 222, 232 are connected to the cell header 410.As mentioned above, the corrugated foil strips 222, 232 may be unitary structures extending from the existing foil strips of the anodes and cathodes, or they may be joined (e.g., by welding) to a strip (self-corrugated or non-corrugated) extending from the anodes and cathodes. In this example, the corrugated foil strips 222, 232 are connected to the elongated foil strips directly connected to the cell holder 410, but in alternative embodiments, the corrugated foil strips 222, 232 may be connected to the anodes and cathodes on opposite or orthogonal sides of the battery cell 400.In another example, FIG. 5A is a diagram of a configuration of a cylindrical battery cell according to various embodiments. Here, the battery cell 500 includes a cathode layer 530 having corrugated foil cathode strips (e.g., strips 532) extending from that layer. The battery cell 500 further includes an anode layer 520 having corrugated foil anode strips extending therefrom (e.g., strips 522). The cathode layer 530 and the anode layer 520 are rolled up in a jelly roll structure 540, the separator layer 510 being arranged therebetween. The jelly roll structure 540 is enclosed by a can 545. Internal lead 550 is connected at one end to the cathode strips and at the other end to cap 555.In some embodiments, the inner conduit 550 may be a unitary extension of the corrugated foil strips (without intervening connection structures) or a separate piece connected to the corrugated foil strips. In some embodiments, the inner conduit 550 is a separate, non-corrugated structure that is bonded to the corrugated foil strips.FIG. 5B is a diagram of another configuration of a cylindrical battery cell according to various embodiments. In this example, the battery cell 560 includes a cathode layer 565 and an anode layer 570 rolled together in a jelly roll structure 575 with a separator layer 567 therebetween. In this example, the cylindrical battery cell 560 includes a relatively larger number of corrugated foil strips than the pattern in FIG. 5A, where the spacing between the individual strips is substantially less than the pattern in FIG. 5A. In this example, the corrugated foil strips extending from the cathode layer 565 (e.g., strip 532) and the anode layer 570 (e.g., strip 522) are crimped or welded to the top and bottom surfaces of the can 545.FIG. 6 is a side view of an alternative embodiment of a corrugated foil strip according to one or more embodiments of the present disclosure. In this example, configurations 610- 650 represent side views of example corrugation configurations (e.g., in the x-y plane). Configuration 610, for example, represents an angular corrugation pattern in which the alternating peaks and valleys are symmetrical and the peaks and valleys have an angle of less than ninety degrees. Configuration 620 illustrates a trapezoidal corrugation configuration in which the alternating peaks and valleys have an elongated flattened portion. Configuration 630 provides an example of a mixed angular and trapezoidal configuration in which the vertices are angular and the troughs are trapezoidal.Embodiments of the present disclosure may also use other corrugation designs. For example, configuration 640 represents a corrugation configuration with more angled peaks and valleys than configuration 610 where the peaks and valleys tilt (to the right in this example). The geometry of the corrugated foil strips used in connection with embodiments of the present disclosure may be symmetrical (as shown in embodiments 610 and 620) or asymmetrical as shown in embodiment 650 where the alternating peaks and valleys do not have the same amplitude.In some embodiments, asymmetric corrugation may be used such that different voids within a cell may accommodate different corrugation structures. For example, the end of a corrugation pattern of decreasing size or height (as shown in the right portion of the configuration 650) may be advantageously used at the edges of a weld area, while the other end of the corrugation may be used with a relatively large size or height (as shown in the left portion of the configuration 650) at the electrode edges where the large void may accommodate the corrugation structure.FIG. 7 illustrates an example of the dimensions and geometry of a corrugated foil strip according to various embodiments. In this example, the periodic unit wave pattern is illustrated in configuration 610 of FIG. 6. Here, the film 710 is shown prior to corrugation to have the effective length L0in a first plane (e.g., x-plane) and a thickness T in a second plane (e.g., y-plane). As introduced above, the film 710 further has a width (not shown in FIG. 7 ) in a third plane (e.g., the z-plane), wherein the first plane, the second plane, and the third plane are orthogonal to each other in a three-dimensional configuration. In some embodiments, the length L0may be less than about 30 mm and may be configured based on the available space in the cells of a particular battery. The variables associated with the periodic unit wave pattern in Embodiment 610 are as follows:h: Height of periodic unit waveα: Angle of Periodic Unit Wavea: half the wavelength in a corrugated foil strip: a=h*tan(α / 2)La: 1⁄4 Periodic Unit Wave Length: La=h / cos(α / 2)n: Periodic Unit Wave Number: n=L0 / (2a)L: Total length of the film strip in the corrugated portion: L=(2La)*nFor example, in the symmetrical angled corrugated foil strip 610 illustrated in FIG. 7, when the effective length is 5 mm, the height of the unit wave is 250 μm, the angle of the unit wave is 60°, the number of the unit waves may be calculated as 8, the actual length of the foil strip may be calculated as 10 mm. Thus, in analogy to the corrugation pattern in Fig. 7 to a sine wave, the width of the band gap of the wave is determined by the height of the periodic unit wave (h) and the angle of the periodic unit wave (α). The number, height, angle and band gap of the periodic corrugated corrugations and the total length of the corrugated foil strip may be determined for manufacturing and quality control.In the case of non-symmetric or irregular corrugation of a foil strip, as illustrated in configuration 650 in FIG. 6, the actual length of the foil strip may be estimated based on the similar symmetric triangular wave and then adjusted based on the available void space within the cell. Another way to estimate the actual length of the film strip may be based on the measurement of the energy input during the shock or vibration test. For example, in some embodiments, a Cu foil strip having a corrugated structure (5 mm displacement) according to embodiments of the present disclosure may improve energy absorption by over 500%. Similarly, an Al foil strip having a corrugated structure (4 mm displacement) according to the embodiments of the present disclosure may improve the energy absorption by over 450%. Thus, if 10 times the energy consumption is required, 8 to 10 mm more of Cu or Al foil strips may be required. The width of the band gap may be estimated based on the effective length and the actual length of the single film strip. In some embodiments, the actual length of the terminal strips for a corrugated terminal strip may also be estimated based on the energy consumption requirement.The terms "a" and "an" do not mean a quantity limitation, but rather denote the presence of at least one of the stated objects. The term "or" means "and / or" unless the context clearly indicates otherwise. Throughout the specification, when "one aspect" is mentioned, it means that a particular element (e.g., feature, structure, step, or characteristic) described in connection with the aspect is included in at least one of the aspects described herein and may or may not be present in other aspects and may or may not be present in other aspects. It is also understood that the described elements may be combined in any suitable manner in the various aspects.When an element such as a layer, film, region or substrate is referred to as being "on" another element, it may be directly on the other element or intervening elements may also be present. In contrast, there are no intervening elements when an element is referred to as being "directly on" another element.Unless otherwise specified herein, all testing standards are the latest standard in effect on the filing date of this application or, if a priority is claimed, the filing date of the earliest priority application in which the testing standard appears.Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.Although the above disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes may be made and equivalent elements may be substituted without departing from the scope thereof. Moreover, many changes may be made to adapt a particular situation or material to the teachings of the disclosure without departing from its essential scope. Therefore, the present disclosure is not intended to be limited to the particular embodiments, but to include all embodiments falling within its scope.

Claims

A battery cell comprising: a cathode; an anode; and a corrugated foil strip connected to the cathode or the anode, wherein the corrugated foil strip has a length in a first plane, has alternating peaks and valleys in a second plane along the length of the corrugated foil strip, and has a width in a third plane, and wherein the first plane, the second plane, and the third plane are orthogonal to each other.The battery cell of claim 1, wherein the corrugated foil strip is a first corrugated foil strip connected to the cathode, and the battery cell further comprises a second corrugated foil strip connected to the anode.The battery cell of claim 2, wherein the first corrugated foil strip is connected to the cathode at a first end of the first corrugated foil strip and to a first terminal strip at a second end of the first corrugated foil strip, the first end of the first corrugated foil strip being opposite the second end of the first corrugated foil strip.The battery cell of claim 3, wherein the first corrugated foil strip comprises an insulating coating at the first end of the first corrugated foil strip.The battery cell of claim 4, wherein the insulating coating comprises a polymer and a ceramic material.The battery cell of claim 4, wherein the insulating coating has a thickness of about 5 micrometers to 40 micrometers.The battery cell of claim 3, wherein the first corrugated foil strip comprises a polymer coating on the second end of the first corrugated foil strip, the polymer coating comprising one or more of: a thermoplastic, polytetrafluoroethylene (PTFE), polyvinyl chloride (PVC), polyurethane, acrylonitrile butadiene rubber (NBR), a polytetrafluoroethylene / butyl rubber blend, a nylon 6 / polypropylene blend, and an interpenetrating urethane / acrylate polymer network.The battery cell of claim 7, wherein the polymeric coating on the second end of the first corrugated foil strip has a thickness of about one micrometer and two micrometers.The battery cell of claim 3, wherein the second corrugated foil strip is connected to the anode at a first end of the second corrugated foil strip and to a second terminal strip at a second end of the second corrugated foil strip, the first end of the second corrugated foil strip being opposite the second end of the second corrugated foil strip.The battery cell according to claim 1, wherein the battery cell has a pouch cell shape, a prismatic cell shape, or a cylindrical cell shape.

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