# US 2025/0385397 A1 · Folded lead tabs > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2025/0385397 A1 - Document ID: US20250385397A1 - Status: Published application - Kind: A1 - Application number: 19/210,735 - Filed: 2025-05-16 - Published: 2025-12-18 - Earliest claimed: 2024-06-13 - Assignees: Apple Inc. - Applicants: Apple Inc. - Inventors: Samuel C. Billand; Pranjal K. Naik; Steven M. Labovitz; Karl A. Gazdowski - Web page: https://patentgrep.com/patent/US20250385397A1 ## CPC - H01M 50/533: characterised by the shape of the leads or tabs - H01M 4/661: {Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence)} - H01M 50/528: Fixed electrical connections, i.e. not intended for disconnection - H01M 50/536: characterised by the method of fixing the leads to the electrodes, e.g. by welding - H01M 50/54: Connection of several leads or tabs of plate-like electrode stacks, e.g. electrode pole straps or bridges - Y02E 60/10: Energy storage using batteries - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract Aspects of the present disclosure involve folded electrode tabs. In general, a battery pack includes a battery cell, an enclosure enclosing the battery cell, a feedthrough tab configured to form a battery terminal, and a lead tab. The battery cell includes a stack of electrodes and a plurality of electrode tabs extending from the stack of electrodes. The lead tab includes a first portion connected to the plurality of electrode tabs, a second portion connected to the feedthrough tab, and a third portion connecting the first portion to the second portion such that the first portion and the second portion at least partially overlap and reside in substantially separate parallel planes. The plurality of electrode tabs extend from the stack of electrodes in a direction that is substantially parallel to both the first portion and the second portion. ## Claims ### Claim 1 A battery pack comprising: a battery cell comprising: a stack of electrodes; and a plurality of electrode tabs extending from the stack of electrodes; an enclosure enclosing the battery cell; a feedthrough tab configured to form a battery terminal; and a lead tab comprising: a first portion connected to the plurality of electrode tabs; a second portion connected to the feedthrough tab; and a third portion connecting the first portion to the second portion such that the first portion and the second portion at least partially overlap and reside in substantially separate parallel planes, wherein the plurality of electrode tabs extend from the stack of electrodes in a direction that is substantially parallel to both the first portion and the second portion. ### Claim 2 (depends on 1) The battery pack of claim 1, wherein the third portion connecting the first portion to the second portion forms a substantially 180 degree angle. ### Claim 3 (depends on 1) The battery pack of claim 1, wherein each electrode tab of the plurality of electrode tabs is a cathode current collector. ### Claim 4 (depends on 3) The battery pack of claim 3, further comprising an insulator surrounding the feedthrough tab and configured to electrically isolate the feedthrough tab from the enclosure. ### Claim 5 (depends on 3) The battery pack of claim 3, wherein each cathode current collector is a material comprising aluminum. ### Claim 6 (depends on 1) The battery pack of claim 1, each electrode tab of the plurality of electrode tabs is an anode current collector. ### Claim 7 (depends on 6) The battery pack of claim 6, wherein each anode current collector is a material comprising at least one of copper and nickel. ### Claim 8 (depends on 1) The battery pack of claim 1, wherein the first portion is connected to the plurality of electrode tabs via ultrasonic welding. ### Claim 9 (depends on 1) The battery pack of claim 1, wherein the second portion is connected to the feedthrough tab via laser welding. ### Claim 10 (depends on 1) The battery pack of claim 1, wherein the first portion, the second portion, and the third portion of the lead tab form a service loop, wherein the service loop is configured to absorb a mechanical impact on the enclosure to prevent a failure of the stack of electrodes. ### Claim 11 A method comprising: connecting a first portion of a lead tab to a plurality of electrode tabs extending from a stack of electrodes; connecting a second portion of the lead tab to a feedthrough tab configured to form a battery terminal; and inserting the stack of electrodes within an enclosure by rotating a third portion of the lead tab around a fixed point such that the first portion and the second portion at least partially overlap and reside in substantially separate parallel planes, wherein the plurality of electrode tabs extend from the stack of electrodes in a direction that is substantially parallel to both the first portion and the second portion. ### Claim 12 (depends on 11) The method of claim 11, wherein the third portion connecting the first portion to the second portion is rotated around the fixed point such that the third portion forms a substantially 180 degree angle. ### Claim 13 (depends on 11) The method of claim 11, wherein the third portion connects the first portion to the second portion. ### Claim 14 (depends on 11) The method of claim 11, wherein each electrode tab of the plurality of electrode tabs is a cathode current collector. ### Claim 15 (depends on 14) The method of claim 14, wherein each cathode current collector is a material comprising aluminum. ### Claim 16 (depends on 11) The method of claim 11, wherein each electrode tab of the plurality of electrode tabs is an anode current collector. ### Claim 17 (depends on 16) The method of claim 16, wherein each anode current collector is a material comprising at least one of copper and nickel. ### Claim 18 (depends on 11) The method of claim 11, wherein connecting the first portion of the lead tab to the plurality of electrode tabs extending from the stack of electrodes comprises attaching the first portion of the lead tab to the plurality of electrode tabs extending from the stack of electrodes via ultrasonic welding. ### Claim 19 (depends on 11) The method of claim 11, wherein connecting the second portion of the lead tab to the feedthrough tab comprises laser welding the second portion of the lead tab to the feedthrough tab. ### Claim 20 (depends on 11) The method of claim 11, wherein the first portion, the second portion, and the third portion of the lead tab form a service loop, wherein the service loop is configured to absorb a mechanical impact on the enclosure to prevent a failure of the stack of electrodes.