Abstract: The subject invention provides a battery pouch or container which is highly resistant to shorting. This electrical protection is produced by a folding of the packaging laminate such that the cut edge of the laminate is physically removed and electrically protected from the electrode tab which protrudes from the battery pouch. In one embodiment, the cut edge of the film is folded away from the electrode tab. In a preferred embodiment, the laminar packaging material includes a convex flap of material where the electrode traverses the package. The convex flap is folded away from the electrode tab without wrinkling or distorting the pouch shape. In an alternate embodiment, an intervening layer of insulative material is placed between the cut edge and the electrode tab.

Abstract: The subject invention discloses apparatus and methods to provide compression of an electrochemical cell independent of atmospheric pressure. One aspect of this invention is directed towards a lithium ion cell assembly which is surrounded by a layer of material under tension, so that the material applies pressure which compresses the cell to enhance contact between the anode, separator, and cathode layers. Specifically, a heat shrink material (material which reduces in size, or contracts in at least one dimension of a three-dimensional conformation, due to the application of heat) is provided about a laminar battery and shrunk in situ to provide a battery package. Another embodiment of this invention is directed towards a lithium ion cell asembly in which a sealed package contains both the battery and a spring element. The spring element within the package applies pressure to the battery to compress it and improve contact between the anode, separator, and cathode layers.

Abstract: In order to maintain electrical contact between the anode, cathode and electrolyte layers in an electrochemical cell, a layer of material under tension is wrapped around the cell so that the material compresses the layers together to ensure sufficient electrical contact. Alternatively, a metal, foam or inflatable gas spring is employed in a housing structure containing the electrochemical cell to apply a compressive force to achieve the same result.

Abstract: A battery module has a current collecting spacer positioned between two sides of a folded laminate including a first electrode layer. Top and bottom opposite electrode layers, of opposite polarity from the first electrode layer, are formed on the top and bottom of the folded laminate such that, when the opposite electrode layers and the folded laminate are compressed around the spacer, each opposite electrode layer forms, with a portion of the folded laminate, a substantially planar surface. A method for making the battery module is also described.