Battery cell with increased tab area and method and apparatus for manufacturing same

A method of forming batteries, comprising:

• feeding a first foil through a first coating machine, wherein movement of the first foil defines a foil direction;
• applying a first coating band to the first foil;
• applying a second coating band to the first foil, wherein the second coating band is spaced from the first coating band by a first tab gap;
• cutting the first foil substantially perpendicular to the foil direction to separate a first coated blank;
• cutting the first coated blank to:
• separate the first coating band and a first portion of the first tab gap, to form a first electrode having a first tab;
• and
• separate the second coating band and a second portion of the first tab gap, to form a second electrode having a second tab,
• wherein a length of the first electrode and the second electrode is aligned with the foil direction and a width of the first electrode and the second electrode is substantially perpendicular to the foil direction, and wherein the length to width ratio of the first electrode and the second electrode is at least five;
• feeding a second foil through a second coating machine, wherein movement of the second foil defines a foil direction;
• applying a third coating band to the second foil;
• applying a fourth coating band to the second foil, wherein the fourth coating band is spaced from the third coating band by a second tab gap;
• cutting the second foil substantially perpendicular to the foil direction to separate a second coated blank;
• cutting the second coated blank to:
• separate the third coating band and a first portion of the second tab gap, to form a third electrode having a third tab;
• and
• separate the fourth coating band and a second portion of the second tab gap, to form a fourth electrode having a fourth tab,
• wherein a length of the third electrode and the fourth electrode is aligned with the foil direction and a width of the third electrode and the fourth electrode is substantially perpendicular to the foil direction, and wherein the length to width ratio of the third electrode and the fourth electrode is at least five;
• and
• pairing the first electrode and the third electrode to form a first mono cell, wherein the first tab and the third tab are on opposite sides of the width of the first electrode and the third electrode.