PACKAGE FOR LARGE FORMAT LITHIUM ION CELLS
A battery cell is disclosed. The battery cell includes a sealed foil pouch having a plurality of openings and a terminal block disposed within the sealed foil pouch. The terminal block has a plurality of terminals extending outwardly therefrom. Each of the plurality of terminals extends through one of the plurality of openings. A method of making the battery cell is also disclosed.
1 . A battery cell comprising:
a sealed foil pouch having a plurality of openings;
a terminal block disposed within the sealed foil pouch, the terminal block having a plurality of terminals extending outwardly therefrom, each of the plurality of terminals extending through one of the plurality of openings.
2 . The battery cell according to claim 1 , further comprising a relief valve extending through one of the plurality of openings.
3 . The battery cell according to claim 1 , further comprising a seal sealingly coupling the terminal block to the foil pouch around each of the plurality of openings.
4 . The battery cell according to claim 1 , wherein the terminal block is fabricated from an electrically non-conductive material.
5 . The battery cell according to claim 1 , further comprising a seal wherein each of the plurality of terminals is sealed against the terminal block.
6 . The battery cell according to claim 1 , further comprising a lid disposed over foil pouch, the lid having a plurality of lid openings, each of the plurality of terminals extending through a respective one of the plurality of lid openings.
7 . The battery cell according to claim 1 , wherein the foil pouch is sealed to itself along three sides.
8 . The battery cell according to claim 7 , wherein the foil pouch is sealed to the terminal block.
9 . The battery cell according to claim 7 , wherein the foil pouch is a continuous laminate along a top of the terminal block.
10 . A method of manufacturing a battery cell comprising the steps of:
a) forming a plurality of foil laminate openings in a foil laminate;
b) engaging a terminal block with the foil laminate, the terminal block having a plurality of terminal openings formed therein;
c) folding the foil laminate over the terminal block such that each of the plurality of terminal openings communicates with one of the plurality of foil laminate openings;
d) sealing two sides of the foil laminate on either side of the terminal block, leaving an open side of the foil laminate disposed away from the terminal block;
e) inserting a stack of terminal electrodes through the open side, the stack of terminal electrodes having a plurality of terminals, each of the plurality of terminals extending through a respective one of the terminal openings and foil laminate openings;
f) sealing the open side, forming a pouch; and
g) inserting an electrolyte into the pouch.
11 . The method according to claim 10 , wherein step g) comprises inserting the electrolyte through one of the plurality of foil laminate openings.
12 . The method according to claim 11 , further comprising, after step g), the step of inserting a relief valve into the one of the plurality of foil laminate openings.
13 . The method according to claim 10 , wherein step a) comprises forming the plurality of foil laminate openings co-linearly.
14 . The method according to claim 10 , wherein step c) comprises the step of sealing the foil laminate around each of the plurality of terminals.
15 . The method according to claim 10 , further comprising the step of disposing a lid on the foil laminate such that each of the plurality of terminals extends through the lid.
16 . A battery cell manufactured by the method of:
a) forming a plurality of foil laminate openings in a foil laminate;
b) engaging a terminal block with the foil laminate, the terminal block having a plurality of terminal openings formed therein;
c) folding the foil laminate over the terminal block such that each of the plurality of terminal openings communicates with one of the plurality of foil laminate openings;
d) sealing two sides of the foil laminate on either side of the terminal block, leaving an open side of the foil laminate disposed away from the terminal block;
e) inserting a stack of terminal electrodes through the open side, the stack of terminal electrodes having a plurality of terminals, each of the plurality of terminals extending through a respective one of the terminal openings and foil laminate openings;
f) sealing the open side, forming a pouch; and
g) inserting an electrolyte into the pouch.
17 . The battery cell according to claim 16 , wherein step g) is performed by inserting the electrolyte through one of the plurality of foil laminate openings.
18 . The battery cell according to claim 17 , further comprising, after step g), the step of inserting a relief valve into the one of the plurality of foil laminate openings.