Electrode assembly with projecting tab for battery and methods of forming same

A method of forming an electrode assembly, the method comprising:

• providing a jelly roll electrode having a plurality of electrode sheets, the plurality of electrode sheets including an anode sheet, a cathode sheet, and a separator separating the anode sheet from the cathode sheet;
• removing portions of the jelly roll electrode outside a subsection of the plurality of sheets, such that the remaining subsection of the plurality of electrode sheets projects axially from a body portion of the jelly roll electrode;
• forming a tab with the remaining subsection of the plurality of electrode sheets, wherein the tab includes the subsection of the plurality of electrode sheets contacting each other;
• coupling a first conductive tab to the tab, wherein the first conductive tab is configured to electrically couple the jelly roll electrode to a battery terminal;
• and
• injecting an electrolyte into the jelly roll electrode between the anode sheet and the cathode sheet.

A battery comprising:

• a conductive battery casing, the conductive battery casing defining a first battery terminal;
• an electrode assembly within the conductive battery casing and having a centerline axis, the electrode assembly including:
• a jelly roll electrode having a plurality of electrode sheets, the plurality of electrode sheets including an anode sheet, a cathode sheet, and a separator separating the anode sheet from the cathode sheet,
• an electrolyte within the conductive battery casing and disposed between the anode sheet and the cathode sheet of the plurality of electrode sheets, and
• a first tab projecting from an axial end of the plurality of electrode sheets, the first tab including a subsection of the plurality of electrode sheets contacting each other at a first axial end of the jelly roll electrode;
• and
• a first conductive tab coupled to the first tab of the electrode assembly;
• and
• a cell cover positioned at an axial end of the conductive battery casing, and including a second battery terminal formed on a first surface of the cell cover and electrically coupled to the first conductive tab.