Non-rectangular batteries for portable electronic devices

Abstract

The disclosed embodiments provide a battery cell. The battery cell includes a set of layers forming a non-rectangular shape, wherein the set of layers comprises a cathode with an active coating, a separator, and an anode with an active coating. The battery cell also includes a first conductive tab coupled to the cathode and a second conductive tab coupled to the anode. The layers are enclosed in a flexible pouch, and the first and second conductive tabs are extended through seals in the pouch to provide terminals for the battery cell. Furthermore, the non-rectangular shape is created by removing material from one or more of the layers.

1 .- 25 . (canceled) 
     
     
         26 . A battery cell, comprising:
 a set of layers forming a non-rectangular shape, wherein each of the set of layers comprises a cathode with an active coating, a separator, and an anode with an active coating and each of the layers includes at least one rounded corner;   a first conductive tab coupled to the cathode; and   a second conductive tab coupled to the anode, and the first and second conductive tabs extending from the non-rectangular shape.   
     
     
         27 . The battery cell of  claim 26 , wherein the non-rectangular shape is created by removing material from one or more of the layers. 
     
     
         28 . The battery cell of  claim 26 , further comprising a flexible pouch enclosing the set of layers. 
     
     
         29 . The battery cell of  claim 28 ,
 wherein the first and second conductive tabs extend through seals in the flexible pouch to provide terminals for the battery cell.   
     
     
         30 . The battery cell of  claim 26 , wherein the layers each have the same non-rectangular shape. 
     
     
         31 . The battery cell of  claim 26 , wherein the non-rectangular shape comprises two or more thicknesses. 
     
     
         32 . A method for manufacturing a battery cell, comprising:
 obtaining a set of layers for the battery cell, wherein each of the set of layers comprises a cathode with an active coating, a separator, and an anode with an active coating and each of the layers includes at least one rounded corner;   coupling a first conductive tab to the cathode;   coupling a second conductive tab to the anode;   removing material from one or more of the layers to create a non-rectangular shape in the battery cell; and   sealing the layers in a pouch to form the battery cell, wherein the pouch is flexible.   
     
     
         33 . The method of  claim 32 , further comprising:
 performing stacking operations on the set of layers to form a stack.   
     
     
         34 . The method of  claim 32 , further comprising:
 extending the first and second conductive tabs through seals in the pouch to provide terminals for the battery cell.   
     
     
         35 . The method of  claim 32 , further comprising:
 stacking the layers to create a bi-cell prior to sealing the layers in the pouch.   
     
     
         36 . The method of  claim 32 , further comprising:
 winding the layers to create a jelly roll prior to sealing the layers in the pouch.   
     
     
         37 . The method of  claim 32 , wherein removing material from one or more of the layers involves:
 removing the material from one or more sides of the cathode or the anode to form the non-rectangular shape.   
     
     
         38 . A battery pack, comprising:
 a set of battery cells, wherein each of the cells comprises:   a set of layers forming a non-rectangular shape, wherein each of the set of layers comprises a cathode with an active coating, a separator, and an anode with an active coating, and each of the layers includes at least one rounded corner;   a first conductive tab coupled to the cathode; and   a second conductive tab coupled to the anode, the first and second conductive tabs extending from the non-rectangular shape.   
     
     
         39 . The battery pack of  claim 38 , wherein the non-rectangular shape is created by removing material from one or more of the layers. 
     
     
         40 . The battery pack of  claim 38 , wherein each battery cell further comprises:
 a flexible pouch enclosing the layers;   and wherein the first and second conductive tabs extend through seals in the flexible pouch to provide terminals for the battery cell.   
     
     
         41 . The battery pack of  claim 38 , wherein removing material from one or more of the layers involves:
 removing the material from one or more sides of the cathode or the anode to form the non-rectangular shape.   
     
     
         42 . The battery pack of  claim 38 , wherein the layers each have the same non-rectangular shape. 
     
     
         43 . The battery pack of  claim 38 , wherein the non-rectangular shape comprises two or more thicknesses. 
     
     
         44 . The battery pack of  claim 38 , wherein the set of layers is used to create at least one of a jelly roll and a bi-cell. 
     
     
         45 . A portable electronic device, comprising:
 a set of components powered by a battery pack; and
 the battery pack comprising: 
   a set of battery cells, wherein each of the battery cells comprises:
 a set of layers forming a non-rectangular shape, wherein each of the set of layers comprises a cathode with an active coating, a separator, and an anode with an active coating, and each of the layers includes at least one rounded corner, 
 a first conductive tab coupled to the cathode; and 
 a second conductive tab coupled to the anode, and the first and second conductive tabs extending from the non-rectangular shape. 
   
     
     
         46 . The portable electronic device of  claim 45 , wherein the non-rectangular shape is created by removing material from one or more of the layers. 
     
     
         47 . The portable electronic device of  claim 45 , wherein each battery cell in the set of battery cells further comprises:
 a flexible pouch enclosing the layers;   wherein the first and second conductive tabs extend through seals in the flexible pouch to provide terminals for the battery cell.   
     
     
         48 . The portable electronic device of  claim 45 , wherein removing material from one or more of the layers involves:
 removing the material from one or more sides of the cathode or the anode to form the non-rectangular shape.   
     
     
         49 . The portable electronic device of  claim 45 , wherein the layers each have the same non-rectangular shape. 
     
     
         47 . The portable electronic device of  claim 45 , wherein the non-rectangular shape comprises two or more thicknesses.