Battery welds

Patent metadata

Field	Value
Publication number	US-12525671-B2
Application number	US-202318458984-A
Country	US
Kind code	B2
Filing date	Aug 30, 2023
Priority date	Jun 30, 2023
Publication date	Jan 13, 2026
Grant date	Jan 13, 2026

Abstract

Aspects of the subject disclosure relate to various features of a battery subassembly, such as a battery module. The battery subassembly may be implemented in an electric vehicle or in a building. In one or more implementations, the battery subassembly may include a battery cell having a peripheral rim having a first width and forming a terminal for the battery cell; and at least one weld configured to couple the peripheral rim to a connector, in which the at least one weld has a second width that is larger than the first width.

First claim

What is claimed is:

1 . An apparatus, comprising: a battery cell comprising a peripheral rim defining an inner radial edge and an outer radial edge, the peripheral rim having a rim width from the inner radial edge to the outer radial edge and forming a terminal for the battery cell; and at least one weld configured to couple the peripheral rim to a connector, wherein the at least one weld has a weld width that is larger than the rim width such that the at least one weld extends beyond at least one of the inner radial edge or the outer radial edge of the peripheral rim; wherein the rim width is between 0.5 millimeters and 0.8 millimeters, and wherein the weld width is greater than one millimeter.

2 . The apparatus of claim 1 , wherein the battery cell further comprises a gasket disposed at least partially beneath the peripheral rim.

3 . The apparatus of claim 2 , wherein the gasket comprises an asymmetric portion at a location corresponding to the at least one weld.

4 . The apparatus of claim 3 , wherein the at least one weld extends from a top surface of the peripheral rim, through the peripheral rim, to a bottom surface of the peripheral rim.

5 . The apparatus of claim 4 , wherein the at least one weld extends through the bottom surface of the peripheral rim into a portion of the gasket that is disposed beneath the peripheral rim.

6 . The apparatus of claim 1 , wherein the connector comprises a tab of a current collector assembly.

7 . The apparatus of claim 1 , wherein the at least one weld comprises a first set of parallel welds configured to couple the peripheral rim to the connector.

8 . The apparatus of claim 7 , wherein the at least one weld further comprises a second set of parallel welds configured to couple the peripheral rim to the connector.

9 . The apparatus of claim 8 , wherein the at least one weld comprises a third set of parallel welds configured to couple the peripheral rim to the connector.

10 . A battery subassembly, comprising: a current collector assembly comprising an electrically conductive layer and a tab extending from the electrically conductive layer; a battery cell comprising a peripheral rim defining an inner radial edge and an outer radial edge, the peripheral rim having a rim width from the inner radial edge to the outer radial edge and forming a terminal for the battery cell; and at least one weld configured to couple the peripheral rim to the tab, wherein the at least one weld has a weld width that is larger than the rim width such that the at least one weld extends beyond at least one of the inner radial edge or the outer radial edge of the peripheral rim; wherein the rim width is between 0.5 millimeters and 0.8 millimeters, and wherein the weld width is greater than one millimeter.

11 . The battery subassembly of claim 10 , further comprising:
an additional battery cell comprising an additional peripheral rim having the rim width and forming an additional terminal for the additional battery cell; and at least one additional weld that couples the additional peripheral rim of the additional battery cell to the tab, wherein the at least one additional weld has the weld width that is larger than the rim width.

12 . The battery subassembly of claim 10 , further comprising:
a plurality of additional battery cells attached to a plurality of additional respective tabs of the current collector assembly by a plurality of additional respective welds, wherein each of the plurality of additional battery cells has the peripheral rim with the rim width, wherein each of the plurality of additional respective welds has the weld width, and wherein each of a subset of the plurality of additional battery cells comprises a gasket having an asymmetric portion.

13 . The battery subassembly of claim 10 , further comprising:
a plurality of additional battery cells attached to a plurality of additional respective tabs of the current collector assembly by a plurality of additional respective welds, wherein each of the plurality of additional battery cells has the peripheral rim with the rim width, wherein each of the plurality of additional respective welds has the weld width, and wherein each of a subset of the plurality of respective additional welds extends through an entire thickness of a respective peripheral rim of a respective one of the plurality of additional battery cells.

14 . The battery subassembly of claim 10 , further comprising:
a plurality of additional battery cells attached to a plurality of additional respective tabs of the current collector assembly by a plurality of additional respective welds, wherein each of the plurality of additional battery cells has the peripheral rim with the rim width, wherein each of the plurality of additional respective welds has the weld width, wherein each of a first group of the plurality of additional respective welds comprises two sets of additional welds, and wherein each of a second group of the plurality of additional respective welds comprises three sets of additional welds.

15 . A method, comprising: providing a battery cell having a peripheral rim defining an inner radial edge and an outer radial edge, the peripheral rim having a rim width from the inner radial edge to the outer radial edge; aligning a tab of a current collector assembly with a peripheral rim of the battery cell; and welding the tab of the current collector assembly with the peripheral rim of the battery cell by forming at least one weld between the tab and the peripheral rim, the at least one weld having a weld width greater than the rim width, such that the at least one weld extends beyond at least one of the inner radial edge or the outer radial edge of the peripheral rim; wherein the rim width is between 0.5 millimeters and 0.8 millimeters, and wherein the weld width is greater than one millimeter.

16 . The method of claim 15 , wherein forming the at least one weld having the weld width greater than the rim width between the tab and the peripheral rim comprises forming two sets of parallel welds, each of the two sets of parallel welds having the weld width greater than the rim width.

17 . The method of claim 16 , further comprising:
performing a testing operation for the battery cell and the tab following the forming of the two sets of parallel welds; and forming, based on a result of the testing operation, a third set of parallel welds between the peripheral rim and the tab, the third set of parallel welds having the weld width greater than the rim width.

18 . The method of claim 15 , wherein forming the at least one weld having the weld width greater than the rim width between the tab and the peripheral rim comprises melting and partially deforming a portion of a gasket disposed at least partially beneath the peripheral rim.

Assignees

• Rivian Ip Holdings Llc

Inventors

• Kale Varun Milind
• Beecher Bryce Fredrick Alexander
• Gao Tianyue
• Kang Ning
• Yang Jingsi
• Dhiman Rajeev

Classifications

• H01M50/107

  having curved cross-section, e.g. round or elliptic (H01M50/103, H01M50/109, H01M50/11 take precedence) · CPC title

• H01M50/583

  in response to current, e.g. fuses · CPC title

• H01M50/213

  adapted for cells having curved cross-section, e.g. round or elliptic (H01M50/209, H01M50/216 take precedence) · CPC title

• H01M50/664

  Temporary seals, e.g. for storage of instant batteries or seawater batteries · CPC title

• H01M2220/20

  Batteries in motive systems, e.g. vehicle, ship, plane · CPC title