We Claim:
1. An improved battery cell (502, 602, 926) comprising:
a first tab element (904) connected to a cathode of a first pouch cell (912) and a second tab element (920) connected to an anode of the first pouch cell (912);
a first tab element (906) connected to a cathode of a second pouch cell (914) and a second tab element (922) connected to an anode of the second pouch cell (914), wherein the first tab elements (904, 906) and the second tab elements (920, 922) are constructed to have a reduced cross-sectional area forming a fusing element (506a, 706a, 910a, 1002); and
an extended separator (802, 902, 1004) for isolating the fusing element (506a, 706a, 910a, 1002) of the first and second pouch cells (912, 914), wherein the extended separator (802, 902, 1004) acts as an isolator between the fusing elements (506a, 706a, 910a, 1002) either in between the first tab element (904) of the first pouch cell (912) and the first tab element (906) of the second pouch cell (914) or in between the second tab element (920) of the first pouch cell (912) and the second tab element (922) of the second pouch cell (914), thereby providing electrical and thermal isolation.
2. The improved battery cell (502, 602, 926) as claimed in claim 1, wherein the extended separator (802, 902, 1004) within the first and second pouch cells (912, 914) interfaces with the first tab element (904) of the first pouch cell (912) and the first tab element (906) of the second pouch cell (914).
3. The improved battery cell (502, 602, 926) as claimed in claim 1, wherein the extended separator (802, 902, 1004) within the first and second pouch cells (912, 914) interfaces with the second tab element (920) of the first pouch cell (912) and the second tab element (922) of the second pouch cell (914).
4. The improved battery cell (502, 602, 926) as claimed in claim 1, wherein the extended separator (802, 902, 1004) extends below a connection region (806, 908) of the first pouch cell (912) and the second pouch cell (914) wherein the tab elements (506, 516, 706, 804, 904, 906) of the pouch cells (912, 914) are interconnected via the connection region (806, 908).
5. The improved battery cell (502, 602, 926) as claimed in claim 1, wherein a cross- sectional area of the fusing element (506a, 706a, 910a, 1002) is determined based on a maximum current passing through the fusing element (506a, 706a, 910a, 1002) and current density (J) of the fusing element (506a, 706a, 910a, 1002).
6. The improved battery cell (502, 602, 926) as claimed in claim 1, wherein the tab elements (506, 516, 706, 804, 904, 906) are constructed using same material as that of anode or cathode of the first and second pouch cells (912, 914).
7. The improved battery cell (502, 602, 926) as claimed in claim 1, wherein the extended separator (802, 902, 1004) is constructed using ceramic material like alumina (Al2O3), silica (SiO2) or a mica-based material having excellent thermal and electrical insulating properties.
8. The improved battery cell (502, 602, 926) as claimed in claim 1, wherein dimensions of the tab elements (506, 516, 706, 804, 904, 906) are designed based on current flow limit and heating limit of the tab elements (506, 516, 706, 804, 904, 906).
9. The improved battery cell (502, 602, 926) as claimed in claim 1, wherein the extended separator (802, 902, 1004) is a dielectric element.