Abstract: A battery cell includes a plurality of electrodes including a plurality of anode electrodes and a plurality of cathode electrodes. The plurality of electrodes is arranged in one of a stacked architecture and a winding architecture. Each of the plurality of electrodes includes a current collector and active material arranged on opposite sides of the current collector. The current collector of one or more outermost ones of the plurality of electrodes is thicker than the current collectors of remaining ones of the plurality of electrodes having the same anode/cathode type.

Abstract: A non-stick electrode comprises an electrode an electrically insulating sheath disposed thereon. The electrically insulating sheath has an opening on a surface of the electrode through which an electrical current is transmitted or received to or from an opposing electrode respectively. The electrode protrudes through the opening in the insulating sheath. An electrically conducting interlayer is disposed on the electrode such that it contacts the electrode at the opening in the electrically insulating sheath. The electrically conducting interlayer comprises a material that decomposes at a temperature that is greater than a temperature of a metal that is liquified on contact with the non-stick electrode.

Abstract: A method comprises deforming one or more metal foils of a battery between a punch and a die to form bent metal foils. The one or more bent metal foils are disposed in a foil holding fixture with a battery lead disposed next to the one or more bent metal foils such that a bent portion of the one or more bent metal foils are separated from the battery lead by a distance of 0.1 to 2 millimeters. The one or more bent metal foils are impact welded by causing the foils to impact one another or to impact a battery lead at a velocity of speeds of 300 to 900 meters per second.

Abstract: Disclosed herein is a device for magnetic welding of battery boils comprising a coil holder; where the coil holder comprises one or more electrical coils that are operative to be activated by an electrical current; a foil holding fixture; wherein the foil holding fixture comprises a plurality of arms; wherein each pair of adjacent arms is operative to move towards one another to crimp a plurality of battery foils; and an anvil; wherein the anvil is operative to support a battery tab and the battery foils.