BACKGROUND

Batteries can include electrochemical cells to supply electrical power to various electrical components connected thereto. Such batteries can be installed in a vehicle such as an automobile to provide electrical energy to various electrical systems installed within the vehicle.

SUMMARY

At least one aspect is directed to battery cell to power an electric vehicle. The battery cell includes a housing and an electrode structure disposed in the housing. The electrode structure includes a first polarity electrode plate, a second polarity electrode plate, a separator, and a first polarity tab. The first polarity electrode plate includes a first polarity metal plate and a first polarity current collector material disposed on the first polarity metal plate. The second polarity electrode plate includes a second polarity metal plate and a second polarity current collector material disposed on the second polarity metal plate. The separator is positioned between the first polarity electrode plate and the second polarity electrode plate, the separator having pores through which ions are exchanged between the first polarity electrode plate and the second polarity electrode plate. The first polarity tab electrically connects the first polarity electrode plate to a first polarity terminal of the battery cell. The first polarity tab includes an electrode interface surface coupled with the first polarity metal plate of the first polarity electrode plate, a flat surface opposite the electrode interface surface, and at least one intermediate surface that extends between the electrode interface surface and the flat surface and that forms an acute angle with the electrode interface surface. The battery cell is disposed in a battery pack to power an electric vehicle.

At least one aspect is directed to an electric vehicle. The electric vehicle can include a battery pack to power the one or more components of the electric vehicle. The electric vehicle can include a battery cell. The battery cell can be arranged in the battery pack. The battery cell can have a housing and an electrode structure disposed in the housing. The electrode structure includes a first polarity electrode plate, a second polarity electrode plate, a separator, and a first polarity tab. The first polarity electrode plate includes a first polarity metal plate and a first polarity current collector material disposed on the first polarity metal plate. The second polarity electrode plate includes a second polarity metal plate and a second polarity current collector material disposed on the second polarity metal plate. The separator is positioned between the first polarity electrode plate and the second polarity electrode plate, the separator having pores through which ions are exchanged between the first polarity electrode plate and the second polarity electrode plate. The first polarity tab electrically connects the first polarity electrode plate to a first polarity terminal of the battery cell. The first polarity tab includes an electrode interface surface coupled with the first polarity metal plate of the first polarity electrode plate, a flat surface opposite the electrode interface surface, and at least one intermediate surface that extends between the electrode interface surface and the flat surface and that forms an acute angle with the electrode interface surface. The battery cell is disposed in a battery pack to power an electric vehicle.

At least one aspect is directed to a method. The method can include providing battery cells, the battery cell disposed in a battery pack to power an electrical vehicle. The battery cell can include a housing and an electrode structure disposed in the housing. The electrode structure includes a first polarity electrode plate, a second polarity electrode plate, a separator, and a first polarity tab. The first polarity electrode plate includes a first polarity metal plate and a first polarity current collector material disposed on the first polarity metal plate. The second polarity electrode plate includes a second polarity metal plate and a second polarity current collector material disposed on the second polarity metal plate. The separator is positioned between the first polarity electrode plate and the second polarity electrode plate, the separator having pores through which ions are exchanged between the first polarity electrode plate and the second polarity electrode plate. The first polarity tab electrically connects the first polarity electrode plate to a first polarity terminal of the battery cell. The first polarity tab includes an electrode interface surface coupled with the first polarity metal plate of the first polarity electrode plate, a flat surface opposite the electrode interface surface, and at least one intermediate surface that extends between the electrode interface surface and the flat surface and that forms an acute angle with the electrode interface surface. The battery cell is disposed in a battery pack to power an electric vehicle.

At least one aspect is directed to a method of forming an electrode structure of a battery cell. The method can include disposing a first polarity tab on a first polarity electrode plate, the first polarity tab including an electrode interface surface coupled with a first polarity metal plate of the first polarity electrode plate, a flat surface opposite the electrode interface surface, and at least one intermediate surface that extends between the electrode interface surface and the flat surface and that forms an acute angle with the electrode interface surface. The method can include ultrasonically welding the first polarity tab to the first polarity electrode plate by positioning an ultrasonic welding tool on the flat surface of the first polarity tab. The method can include laser ablating weld burrs on the flat surface of the first polarity tab. The method further includes rolling the first polarity electrode plate, a second polarity electrode plate, and a separator separating the first polarity electrode plate and the second polarity electrode plate into an electrode structure.

These and other aspects and implementations are discussed in detail below. The foregoing information and the following detailed description include illustrative examples of various aspects and implementations, and provide an overview or framework for understanding the nature and character of the claimed aspects and implementations. The drawings provide illustration and a further understanding of the various aspects and implementations, and are incorporated in and constitute a part of this specification.

