Abstract: A cell stack includes adjacent first and second battery cells respectively having a positive cell tab, a negative cell tab, and an outer surface. The outer surfaces are flush. The positive cell tab of the first battery cell protrudes from the outer surface of the first battery cell, and the negative cell tab of the second battery cell protrudes from the outer surface of the second battery cell. An isolative shield is positioned adjacent to the outer surfaces, and defines through-slots receiving therein a respective one of the cell tabs. A method includes providing the cell stack, inserting the cell tabs into the pair of through-slots of the isolative shield, positioning a primary surface of the isolative shield adjacent to the outer surfaces of the adjacent battery cells after inserting the cell tabs, and affixing the primary surface of the isolative shield to the cell stack.

Abstract: A battery assembly includes electrode tabs and a multi-piece bus bar cap assembly. A first cap member of the cap assembly has side walls forming a U-shaped cross-section, and radial projections at distal ends. The second cap member has side walls with an M-shaped cross-section at distal ends of the second member, and a U-shaped cross-section extending between the M-shaped distal ends. In a method of making the battery assembly, tab channels receive the electrode tabs. The second cap member defines radial recesses that receive the radial projections to secure the first cap member to the second cap member, and to secure electrode tabs within the tab channels, in conjunction with contact between the cap members, when the first cap member is moved toward the floor of the second cap member.

Abstract: A cell stack includes adjacent first and second battery cells respectively having a positive cell tab, a negative cell tab, and an outer surface. The outer surfaces are flush. The positive cell tab of the first battery cell protrudes from the outer surface of the first battery cell, and the negative cell tab of the second battery cell protrudes from the outer surface of the second battery cell. An isolative shield is positioned adjacent to the outer surfaces, and defines through-slots receiving therein a respective one of the cell tabs. A method includes providing the cell stack, inserting the cell tabs into the pair of through-slots of the isolative shield, positioning a primary surface of the isolative shield adjacent to the outer surfaces of the adjacent battery cells after inserting the cell tabs, and affixing the primary surface of the isolative shield to the cell stack.