Battery cell tabs with a unitary seal

Abstract

The disclosed technology relates to a set of battery tabs. The battery tabs include a first tab forming an elongated member, a second tab forming an elongated member, and a unitary seal surrounding a portion of the respective elongated members of the first tab and the second tab. The unitary seal spaces the first tab apart from the second tab to create a gap between the first tab and the second tab. The first tab and second tab each connect to respective electrodes enclosed within a pouch of a battery cell to allow the cell's energy to be transferred to an external component.

What is claimed is: 
     
         1 . A set of battery tabs, comprising:
 a first tab forming an elongated member;   a second tab forming an elongated member; and   a unitary seal surrounding a portion of the respective elongated members of the first tab and the second tab, wherein the unitary seal spaces the first tab apart from the second tab to create a gap between the first tab and the second tab.   
     
     
         2 . The set of battery tabs of  claim 1 , wherein the unitary seal positions the second tab in parallel with the first tab. 
     
     
         3 . The set of battery tabs of  claim 1 , wherein the gap is 2.5 to 3.5 mm. 
     
     
         4 . The set of battery tabs of  claim 1 , wherein the first tab comprises a first conductive material and the second tab comprises a second conductive material, wherein the second material is different from the first material. 
     
     
         5 . The set of battery tabs of  claim 4 , wherein the first material comprises a conductive material electro-chemically stable at the voltage potential of a battery anode and the second material comprises a conductive material electro-chemically stable at the voltage potential of a battery cathode. 
     
     
         6 . The set of battery tabs of  claim 4 , wherein the first material comprises at least one of copper, copper-plated aluminum, nickel, titanium, and platinum. 
     
     
         7 . The set of battery tabs of  claim 4 , wherein the second material comprises at least one of aluminum, zinc, and iron. 
     
     
         8 . The set of battery tabs of  claim 1 , wherein the unitary seal is composed of at least one of polypropylene, copolymers, polyamide resins, polyester resins, ionomers, poly urethane resins, polyethylene resin, nutrient cellophane, actate film, vinyl chloride film, polyvinylidene chloride film, polystyrene film, polycarbonate film, nylon film, and polyethylene cellophane. 
     
     
         9 . A battery cell, comprising:
 a plurality of layers, wherein the plurality of layers comprise an anode with an active coating, a separator, and a cathode with an active coating;   a pouch enclosing the plurality of layers, wherein a portion of a periphery of the pouch is sealed; and   a set of tabs extending from the pouch, wherein the set of tabs comprises:   a first tab forming an elongated member and comprised of a first material, the first tab coupled to the anode within the pouch;   a second tab forming an elongated member and comprised of a second material, the second material being different from the first material, the second tab coupled to the cathode within the pouch; and   a unitary seal surrounding the first tab and second tab, the unitary seal abutting the sealed periphery portion of the pouch.   
     
     
         10 . The battery cell of  claim 9 , wherein the unitary seal and a portion of the periphery of the pouch create a hermetic seal. 
     
     
         11 . The battery cell of  claim 9 , wherein the unitary seal spaces the first tab apart from the second tab to create a gap between the first tab and the second tab; and wherein the gap is 2.5 to 3.5 mm. 
     
     
         12 . The battery cell of  claim 9 , wherein the first material comprises a conductive material electro-chemically stable at the voltage potential of the anode and the second material comprises a conductive material electro-chemically stable at the voltage potential of the cathode. 
     
     
         13 . The battery cell of  claim 9 , wherein the first material comprises at least one of copper, copper-plated aluminum, nickel, titanium, and platinum. 
     
     
         14 . The battery cell of  claim 9 , wherein the second material comprises at least one of aluminum, zinc, and iron. 
     
     
         15 . The battery cell of  claim 9 , wherein the unitary seal is composed of at least one of polypropylene, copolymers, polyamide resins, polyester resins, ionomers, poly urethane resins, polyethylene resin, nutrient cellophane, actate film, vinyl chloride film, polyvinylidene chloride film, polystyrene film, polycarbonate film, nylon film, and polyethylene cellophane. 
     
     
         16 . A method for manufacturing a roll of anode and cathode tabs, the method comprising:
 placing a strip of anode material adjacent to a strip of cathode material;   applying a sealing material across both the strip of anode material and the strip of cathode material to form a first unitary seal;   applying the sealing material across both the strip of anode material and the strip of cathode material to form a second unitary seal, the first unitary seal disposed vertically above the second unitary seal; and   rolling the strip of anode material and the strip of cathode material to form a roll of anode material and cathode material intermittently connected by the sealing material.   
     
     
         17 . The method of  claim 16 , wherein the first unitary seal and the second unitary seal space the strip of anode material apart from the strip of cathode material to create a gap between the strip of anode material and the strip of cathode material; and wherein the gap is about 2.5 to 3.5 mm. 
     
     
         18 . The method of  claim 16 , wherein the strip of anode material comprises at least one of copper, copper-plated aluminum, nickel, titanium, and platinum. 
     
     
         19 . The method of  claim 16 , wherein the strip of cathode material comprises at least one of aluminum, zinc, and iron. 
     
     
         20 . The method of  claim 16 , wherein the first and second unitary seal is composed of a sealing material and the sealing material is composed of at least one of polypropylene, copolymers, polyamide resins, polyester resins, ionomers, poly urethane resins, polyethylene resin, nutrient cellophane, actate film, vinyl chloride film, polyvinylidene chloride film, polystyrene film, polycarbonate film, nylon film, and polyethylene cellophane.