Abstract: A method of forming battery leads, comprising the steps of: forming a plurality of aligned, spaced-apart elongated openings in a rectangular, metallic sheet, the metallic sheet having side edges and a width between the side edges equal to a desired length of a battery lead, the openings extending between the side edges and being aligned in a row that extends parallel to the side edges; treating areas of the surfaces of the metallic sheet between the openings to enhance the adhesive properties thereof; applying a strip of an adhesive/sealant material to each side of the metallic strip over the area and the slots; and cutting a battery lead from the metallic sheet by cutting the metallic sheet widthwise through each opening from one side edge to the other side edge.

Abstract: A method of connecting a generally flat battery lead to at least one flat current collector of a polymer battery, comprising the steps of: bending a generally planar lead about at least one generally planar current collector tab to form a layered area, wherein at least one planar tab is disposed between planar portions of the lead with the lead wrapped around one edge of at least one tab; clamping the layered area between two weld fixtures of an ultrasonic welder; and vibrating the weld fixtures to ultrasonically weld together the battery lead and at least one current collector tab.

Abstract: A Li-ion and/or Li-ion polymer cell, comprised of a first cathode section and a second cathode section. Each cathode section has a cathode current collector in contact therewith. The cathode current collector is comprised of a sheet of metal mesh having a tab portion that extends outwardly from the sheet beyond the cathode section. The cathode tab from the first cathode section is disposed adjacent to the cathode tab from the second cathode section. An anode section is disposed between the cathode sections. The anode section has an anode current collector having a tab portion that extends therefrom beyond the anode section. A separator layer is disposed between the anode section and each of the cathode sections. A protective band is disposed between the tabs of each cathode current collector. The protective band is disposed between the cathode tabs and the anode section to prevent shorts when the cathode tabs are pressed together to form a single positive lead.

Abstract: A method of forming battery leads, comprising the steps of: forming a plurality of aligned, spaced-apart elongated openings in a rectangular, metallic sheet, the metallic sheet having side edges and a width between the side edges equal to a desired length of a battery lead, the openings extending between the side edges and being aligned in a row that extends parallel to the side edges; treating areas of the surfaces of the metallic sheet between the openings to enhance the adhesive properties thereof; applying a strip of an adhesive/sealant material to each side of the metallic strip over the area and the slots; and cutting a battery lead from the metallic sheet by cutting the metallic sheet widthwise through each opening from one side edge to the other side edge.

Abstract: A method of connecting a generally flat battery lead to at least one flat current collector of a polymer battery, comprising the steps of: bending a generally planar lead about at least one generally planar current collector tab to form a layered area, wherein at least one planar tab is disposed between planar portions of the lead with the lead wrapped around one edge of at least one tab; clamping the layered area between two weld fixtures of an ultrasonic welder; and vibrating the weld fixtures to ultrasonically weld together the battery lead and at least one current collector tab.

Abstract: A Li-ion and/or Li-ion polymer cell, comprised of a first cathode section and a second cathode section. Each cathode section has a cathode current collector in contact therewith. The cathode current collector is comprised of a sheet of metal mesh having a tab portion that extends outwardly from the sheet beyond the cathode section. The cathode tab from the first cathode section is disposed adjacent to the cathode tab from the second cathode section. An anode section is disposed between the cathode sections. The anode section has an anode current collector having a tab portion that extends therefrom beyond the anode section. A separator layer is disposed between the anode section and each of the cathode sections. A protective band is disposed between the tabs of each cathode current collector. The protective band is disposed between the cathode tabs and the anode section to prevent shorts when the cathode tabs are pressed together to form a single positive lead.

Abstract: A Li-ion or Li-ion polymer battery, comprised of a battery assembly having a plurality of generally planar cathode sections, each having a flat, metallic cathode current collector tab extending therefrom. A cathode tab weldment joins the cathode current collector tabs together with a cathode battery lead, and an anode tab weldment joins the anode current collector tabs together with an anode battery lead. A battery package contains the battery assembly with the anode tab weldment and the cathode tab weldment within the package and the anode and cathode battery leads extend through the package. A protective insert within the battery package surrounds the anode and cathode tab weldments and isolates the weldments from the battery package. The insert surrounds the battery leads where the battery leads extend through the package.