Battery cell for an electric vehicle battery pack

A method, comprising:

• providing a battery cell of a battery pack to power an electric vehicle, the battery cell comprising:
• a housing containing an electrolyte material;
• a first polarity terminal disposed at a lateral end of the battery cell;
• a buckling plate disposed at the lateral end of the battery cell and electrically connected with the first polarity terminal, the buckling plate comprising a planar portion and a domed portion, the domed portion having a convex part extending toward the electrolyte material, the domed portion structured to deflect away from the electrolyte material in response to a first predetermined threshold pressure within the battery cell;
• and
• a melting component comprising:
• an inner ring surrounding and electrically coupled with a perimeter of the domed portion of the buckling plate;
• an outer ring surrounding the inner ring and electrically coupled with the electrolyte material, and;
• a plurality of spokes coupling the inner ring with the outer ring, the plurality of spokes to melt in response to at least one of a predetermined threshold temperature and a predetermined threshold current within the battery cell.

A method of providing battery cells for battery packs of electric vehicles, comprising:

• forming a housing for a battery cell of a battery pack having a plurality of battery cells, the housing having a body region and a head region disposed at a lateral end of the battery cell;
• housing, within the body region of the battery cell, an electrolyte material;
• disposing, at the head region of the housing, a first polarity terminal;
• disposing, at the head region of the housing, a buckling plate having a planar portion and a domed portion, the domed portion having a convex part extending the electrolyte material, the domed portion configured to deflect away from the electrolyte material in response to a first predetermined threshold pressure within the battery cell;
• disposing, at the head region of the housing, a melting component to electrically couple an inner ring of the melting component to the domed portion of the buckling plate and to electrically couple an outer ring of the melting component to the electrolyte material, the melting component having a plurality of spokes coupling the inner ring with the outer ring, the plurality of spokes configured to melt in response to either a predetermined threshold temperature or a predetermined threshold current within the battery cell;
• and
• crimping a perimeter edge of the buckling plate around the first polarity terminal to electrically couple the buckling plate to the first polarity terminal.