Battery cell, battery pack, and method of making the same incorporating features that accelerate heat dissipation, improve uniformity of heat distribution, and reduce size

A method of making a battery cell comprising:

• forming a metal layer;
• forming a first plastic layer on one side of the metal layer;
• forming a second plastic layer on the other side of the metal layer, the metal layer and the first and second plastic layers forming a tri-layer structure, wherein at least one of the first and second plastic layers is formed in discontinuous segments along a length of the metal layer such that portions of the metal layer are exposed and the metal layer forming at least one heat dissipation tab;
• cutting the tri-layer structure such that the exposed portions of the metal layer form opposite ends of the tri-layer structure;
• heating a portion of at least one of the first and second plastic layers to form a seal that seals an interior of the battery cell;
• folding the tri-layer structure so that the first plastic layer forms an inner layer of the battery cell and the ends of the tri-layer structure are adjacent to one another;
• and
• bending the at least one heat dissipation tab in a direction perpendicular to side surfaces of the battery cell.

A battery pack comprising:

• a first set of battery cells;
• a second set of battery cells;
• and
• a thermal resistant barrier disposed between the first and second sets of battery cells, the thermal resistant barrier including a polyurethane layer having a first surface and a second surface opposite of the first surface, the first surface of the polyurethane layer directly facing the first set of battery cells, the second surface of the polyurethane layer directly facing the second set of battery cells,
• wherein each battery cell of the first and second sets of battery cells includes:
• an inner plastic layer extending along at least three sides of the battery cell;
• an outer plastic layer extending along the at least three sides of the battery cell;
• and
• a middle metal layer that forms at least one heat dissipation tab, the middle metal layer disposed between the inner and outer plastic layers, the middle metal layer extending along the at least three sides of the battery cell and projecting from at least a fourth side of the battery cell, the at least one heat dissipation tab configured to transfer heat to at least one cooling plate through thermal conduction, the fourth side of the battery cell connecting two of the at least three sides to one another,
• wherein the inner and outer plastic layers are formed in discontinuous segments along a length of the middle metal layer such that portions of the middle metal layer are exposed,
• the inner plastic layer, the outer plastic layer, and the middle metal layer forming a tri-layer structure,
• the tri-layer structure being folded so that the inner plastic layer forms an inner layer of that battery cell and ends of the tri-layer structure are adjacent to one another, and
• wherein the at least one heat dissipation tab is bent in a direction perpendicular to side surfaces of the battery cell and parallel to the at least one cooling plate.