Abstract: Aspects of the subject disclosure relate to battery cells having an electrode roll, and one or more current collectors at one or more ends of the electrode roll. Tabs extending from electrodes of the electrode roll at an end of the electrode roll may be folded into contact with the current collector at that end of the electrode roll, without overlapping the tabs. This may help to reduce the amount of space occupied by the tabs at the ends of the battery cell, which can facilitate an increase in electrode size that allows for an increased energy density and/or power capacity of the battery cell.

Abstract: A structural member for a battery cell may be provided in the form of an I-beam having a central support structure that extends through the middle of the battery cell. One or more electrode stacks may be provided within one or more cavities defined by the structural member. The structural member may provide mechanical, structural, and/or thermal benefits for the battery cell and/or one or more battery sub-assemblies, battery modules, and/or battery packs. A battery cell includes a contoured housing with curved lateral surfaces conforming to a shape of one or more wound electrode layers. When the wound electrode layers are inserted into the contoured housing, space between the electrode layers and the contoured housing is reduced, as compared to that of square or rectangular housings, leading to higher wetting rate and lower wetting times of the wound electrode layers, higher structural loading, wider tolerances, and/or flexible cooling strategies.

Abstract: Aspects of the disclosure relate to a battery cell that includes a rolled electrode layer having a coated region, and multiple uncoated extensions that are radially aligned with each other, such as along a direction extending radially from a center of the rolled electrode layer.

Abstract: Described are embodiments of an electrode manufacturing system that pertains to batteries and methods of preparing batteries. In some embodiments, the system includes at least one coater configured to coat a side of an electrode substrate with an electrode slurry to form a coated electrode substrate. The system can also include a multi-pass dryer configured to dry the coated electrode substrate, wherein the web path length of the coated electrode substrate in the dryer is greater than a footprint length of the dryer.