Battery pouch sheet edge insulation

Abstract

A multi-layer laminate sheet suitable to form a battery pouch is described. The laminate sheet includes a core metal layer, a sealant laver, and an insulating layer. The sealant layer is bonded to one surface of the core metal layer, and the insulating layer is bonded to the other surface of the core metal layer. The insulating layer has a width that is greater than the width of the core metal layer, such that the insulating layer extends past two edges of the core metal layer. When the pouch is formed by folding the laminate sheet, the insulating layer protects the edges of the core metal layer of the laminate sheet from being exposed around the edges or sides of the pouch. Other embodiments are also described and claimed.

What is claimed is: 
     
         1 . A method for manufacturing a multi-layer sheet suitable to form a battery pouch, comprising:
 preparing a metal layer to have a predetermined width;   preparing an insulating layer to be wider than the metal layer;   positioning the insulating layer against the metal layer such that opposing edges of the insulating layer extend past opposing edges of the metal layer, respectively; and   bonding the metal layer to the insulating layer as positioned.   
     
     
         2 . The method of  claim 1 , wherein the insulating layer is approximately 400 microns wider than the metal layer. 
     
     
         3 . The method of  claim 1 , further comprising:
 preparing a sealant layer to have approximately the predetermined width of the metal layer; and   bonding the sealant layer to the metal layer.   
     
     
         4 . A method for manufacturing a battery pouch for housing an electrode assembly, comprising:
 forming a cavity in a multi-layer sheet, the multi-layer sheet having an insulating layer, a sealant layer, and a core metal layer sandwiched by the insulating and sealant layers, wherein the insulating layer is wider than the core metal layer so that a peripheral portion of the insulating layer extends beyond an exposed edge of the core metal layer;   positioning the electrode assembly within the cavity;   folding the multi-layer sheet to form a top section that covers a bottom section in which the cavity is formed; and   sealing the cavity in which the electrode assembly is contained by bonding the sealant layer in the top section to the sealant layer in the bottom section.   
     
     
         5 . The method of  claim 4 , further comprising:
 folding the peripheral portion of the insulating layer over so as to cover the exposed edge of the core metal layer.   
     
     
         6 . The method of  claim 4 , wherein sealing the cavity comprises:
 applying heat and pressure to the insulating layer in the top and bottom sections.