Method for fabrication of ultra lightweight, high power density lithium ion batteries

A high voltage lithium ion battery, comprising:

• a plurality of battery cells electrically connected in series, wherein each of the battery cells comprises:
• an active structure including an anode electrode, a cathode electrode, and a separator material arranged between the anode electrode and the cathode electrode;
• a liquid electrolyte;
• and
• a non-metallic pouch arranged to encapsulate the active structure and the liquid electrolyte.

A method of fabricating a lightweight high power battery, the method comprising:

• fabricating an anode structure by bonding a first portion of a metal backing of an anode electrode to a first non-metallic pouch foil, wherein the first non-metallic pouch foil includes an opening to expose a second portion of the metal backing of the anode electrode when bonded to the first non-metallic pouch foil;
• fabricating a cathode structure by bonding a first portion of a metal backing of cathode electrode to a second non-metallic pouch foil, wherein the second non-metallic pouch foil includes an opening to expose a second portion of the metal backing of the cathode electrode when bonded to the second non-metallic pouch foil;
• arranging a separating material between the anode structure and the cathode structure;
• bonding the first non-metallic pouch foil to the second non-metallic pouch foil to create a pouch;
• adding a liquid electrolyte to the pouch;
• and
• sealing the pouch to encapsulate the liquid electrolyte within the pouch.