Battery strip structure, battery comprising strip structure and battery assembly

Abstract

A battery includes a housing, a plurality of cells disposed within the housing, and a set of strip structures. Each cell includes a plurality of positive plates and a plurality of negative plates, and each respective plate has a respective tip. The set of strip structures comprises one or more first strip structures, the one or more first strip structures comprise a positive electrode strip line, a negative electrode strip line and at least two bridging lines, and the at least two bridging lines are arranged between the positive electrode strip line and the negative electrode strip line and connected with the positive electrode strip line and the negative electrode strip line. And the negative electrode strip line is connected with the corresponding tips of the plurality of negative electrode plates in the battery core. And the positive strip lines are connected with the corresponding tips of the plurality of positive plates in different battery cells. A first strip structure, a set of strip structures, and a method of manufacturing a battery are also provided.

Description

Technical Field

[0001] The present disclosure relates generally to batteries. More particularly, the disclosed subject matter relates to battery strip structures for use in batteries such as lead-acid batteries, batteries or battery assemblies including the strip structures, and methods for making such batteries or battery assemblies. Background Art

[0002] Batteries are provided for storing electrical energy for use in vehicles. Lead-acid batteries, nickel-metal hydride batteries, and lithium-ion batteries are three types of batteries that are potentially used in electric vehicles (EVs), hybrid electric vehicles (HEVs), and plug-in hybrid electric vehicles (PHEVs). Although lithium-ion batteries have high specific energy (watt-hours per kilogram, Wh / kg) and have been widely used in small electronic devices such as mobile phones and laptops, their high cost, performance, abuse resistance, and cycle life limit their use in EVs, HEVs, and PHEVs. Lithium-ion batteries are expensive and difficult to recycle. Although nickel-metal hydride batteries have been used in HEVs, they are high in cost and have low specific energy and battery efficiency.

[0003] Most of the current automotive batteries are lead-acid batteries, which benefit from their low price, high power, strong reliability and 98% recycling characteristics. However, the low specific energy and short cycle life of current commercial lead-acid batteries hinder their use in EV, HEV and PHEV applications. If the specific energy and cycle life of lead-acid batteries can be greatly improved, lead-acid batteries should have great advantages over other types of batteries. Therefore, it is expected to develop advanced lead-acid batteries with low cost, high specific energy and long cycle life for use in EV, HEV, PHEV, golf carts and other applications. Summary of the invention

[0004] The present disclosure provides a unique strip structure, a group of strip structures including the strip structure, a battery or battery assembly including the strip structure, and a method of manufacturing a battery or battery assembly.

[0005] According to some embodiments, a battery is provided. This battery may be a lead-acid battery, which is rechargeable in some embodiments. This battery includes a housing, a plurality of battery cells disposed in the housing, and a group of strip structures. Each of the plurality of battery cells includes a plurality of positive plates and a plurality of negative plates. Each corresponding electrode plate has a corresponding tip. The housing (or battery box) may include a battery cell separator for accommodating the battery cells. The group of strip structures is disposed above the electrode plate and connected to the tip of the electrode plate.

[0006] The set of strip structures includes one or more first strip structures (or first type of strip structures). The first strip structure includes a positive strip line, a negative strip line, and at least two bridge lines, which are arranged between the positive strip line and the negative strip line and connected to the positive strip line and the negative strip line. The negative strip line is connected to the corresponding tips of the plurality of negative plates in the first battery cell. The positive strip line is connected to the corresponding tips of the plurality of positive plates in the second battery cell, which is adjacent to and different from the first battery cell.

[0007] In the first strip structure, the positive strip lines and the negative strip lines in the first strip structure are parallel or approximately parallel to each other. Each of the positive strip lines and the negative strip lines has a notch or hole (or multiple holes) configured to cooperate with the electrode tip. For example, the negative strip line has a notch on one side that is configured to cooperate with the corresponding tips of the multiple negative plates in the first battery cell. The positive strip line has a notch on one side that is configured to cooperate with the corresponding tips of the multiple positive plates in the second battery cell. In some embodiments, at least two bridge wires arranged between the positive strip line and the negative strip line are parallel or approximately parallel to each other. The at least two bridge wires can be any suitable number. For example, the first strip structure may include two bridge wires, three bridge wires, or four bridge wires.

[0008] In some embodiments, the group of strip structures further includes a second strip structure and a third strip structure, wherein the second strip structure is connected to a plurality of positive electrodes in a starting cell, and the third strip structure is connected to a plurality of negative electrodes in a terminating cell. The second strip structure is connected to a positive terminal post of the battery. The third strip structure is connected to a negative terminal post of the battery.

[0009] In some embodiments, the set of strip structures further includes a fourth strip structure, which is connected to corresponding tips of multiple negative plates and multiple positive plates from two adjacent cells. In some embodiments, each of the second strip structure, the third strip structure, and the fourth strip structure can be in the shape of a straight strip. The length of the fourth strip structure can be twice the length of the second strip structure or the length of the third strip structure.

[0010] In some embodiments, the fourth strap structure is located at an end of the battery opposite one end of the positive terminal post and the negative terminal post of the battery.

[0011] Each of the set of strip structures is formed of a material selected from the group consisting of lead, lead calcium tin, lead tin, or any combination thereof.

[0012] The battery can include any suitable number of cells. For example, in some embodiments, the battery includes six cells. A set of strip structures includes four strip structures of the first type. A set of strip structures also includes one of each of the second strip structure, the third strip structure, and the fourth strip structure.

[0013] On the other hand, a strip structure and a group of strip structures are provided. This strip structure, that is, the first type of strip structure as described herein, is in a group of strip structures configured to be arranged in a battery. The battery also includes a shell and a plurality of battery cells arranged in the shell. Each of the plurality of battery cells includes a plurality of positive plates and a plurality of negative plates. Each corresponding electrode plate has a corresponding tip. The first strip structure includes a positive strip line, a negative strip line, and at least two bridge wires, which are arranged between the positive strip line and the negative strip line and connected to the positive strip line and the negative strip line. The negative strip line is configured to be connected to the corresponding tips of the plurality of negative plates in the first battery cell. The positive strip line is configured to be connected to the corresponding tips of the plurality of positive plates in the second battery cell, and the second battery cell is different from the first battery cell.

[0014] In some embodiments, the positive strip lines and the negative strip lines in the first strip structure are parallel or approximately parallel to each other. The negative strip lines may have a notch or hole on one side that is configured to cooperate with the corresponding tips of the multiple negative plates in the first battery cell. The positive strip lines may have a notch or hole on one side that is configured to cooperate with the corresponding tips of the multiple positive plates in the second battery cell. In some embodiments, at least two bridge wires arranged between the positive strip lines and the negative strip lines are parallel or approximately parallel to each other. The at least two bridge wires may be two bridge wires, three bridge wires, or four bridge wires. This strip structure is an integrally molded structure or an integrally cast structure, and includes a material selected from the group consisting of lead, lead-calcium-tin, lead-tin, or any combination thereof.

[0015] In another aspect, a method for forming a battery as described herein is provided. The method includes assembling a set of strip structures onto a plurality of cells. The negative strip lines in a first strip structure are connected to corresponding tips of a plurality of negative plates in the first cell. The positive strip lines in the first strip structure are connected to corresponding tips of a plurality of positive plates in the second cell.

[0016] The method also includes placing a set of strip structures and a plurality of cells within the housing to form a partially assembled structure; inverting the partially assembled structure to contact the back side of the cover. The encapsulant is dispensed onto the back side of the cover, which is also inverted. When the components are assembled, the encapsulant is cured to form a resulting battery.

[0017] In some embodiments, the battery is a lead-acid battery. The battery can include any suitable number of cells. In some embodiments, the battery includes six cells, and a set of strip structures includes four first strip structures. In the first strip structure, at least two bridge wires disposed between the positive strip line and the negative strip line are parallel or substantially parallel to each other. The at least two bridge wires include two bridge wires, three bridge wires, or four bridge wires.

[0018] In some embodiments, the set of strip structures further includes a second strip structure and a third strip structure. The step of assembling the set of strip structures onto a plurality of battery cells further includes: connecting the second strip structure to a plurality of positive electrodes in a starting battery cell; and connecting the third strip structure to a plurality of negative electrodes in a terminating battery cell. The set of strip structures further includes a fourth strip structure. The step of assembling the set of strip structures onto a plurality of battery cells further includes: connecting corresponding tips of a plurality of negative plates and a plurality of positive plates from two adjacent battery cells.

[0019] A group of strip structures including the first type of strip structure as described herein and the resulting battery have many advantages. For example, each strip structure is cast or molded into a whole. Compared with the L-shaped through-wall welding process used in the prior art, the amount of lead or lead alloy used is reduced. Since the welding process is not used, the method described herein eliminates the defect rate caused by the through-wall welding process and provides a more stable positive and negative electrode connection. The one-piece casting technology used in this article reduces the internal resistance of the connection and can meet the requirements of higher power discharge. The design of the strip structure significantly improves the corrosion resistance of the strip structure and the resulting battery. In addition, even if a part corrodes, such as a bridge wire breaks due to corrosion, the overall performance of the battery will not be significantly affected. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present disclosure can be best understood from the following detailed description when read in conjunction with the accompanying drawings. It should be emphasized that, according to common practice, the various features of the drawings are not necessarily drawn to scale. On the contrary, the sizes of the various features may be arbitrarily expanded or reduced for clarity. Throughout the specification and drawings, the same reference numerals represent the same features.

[0021] Figure 1 is an exploded view illustrating an exemplary battery according to some embodiments.

[0022] Figure 2 It is a graphic Figure 1 0 is a cross-sectional view of a portion of an exemplary battery including an exemplary strip structure according to some embodiments.

[0023] Figure 3 It is a graphic Figure 1 0 is a cross-sectional view of a portion of an exemplary battery including an exemplary strip structure according to some embodiments.

[0024] Figure 4 yes Figure 3 An enlarged view of a portion of .

[0025] Figures 5 and 6 It is shown Figure 1 A cross-sectional view of two terminal posts in an exemplary battery.

[0026] Figure 7 It is shown Figure 1 A perspective view of an exemplary battery case in an exemplary battery of FIG.

[0027] Figures 8 to 9 is a perspective view showing an exemplary battery cell in some embodiments.

[0028] Fig.10 It is shown Figures 8 to 9 A plan view of an exemplary battery cell in FIG.

[0029] Fig.11 is a plan view showing a set of exemplary strip structures according to some embodiments.

[0030] Fig.12 is a perspective view showing an exemplary strip structure according to some embodiments.

[0031] Fig.13 is a perspective view illustrating a structure having a set of exemplary strip structures disposed on a series of cells of a battery, according to some embodiments.

[0032] Figure 14 to Figure 15 The icon is set in Figure 7 In the battery box Fig.13 perspective view of the structure.

[0033] Fig.16 It is a graphic Fig.15 Top plan view of the structure.

[0034] Fig.17 It is a graphic Fig.15 A perspective view of a structure inverted for assembly with a cover having an encapsulant.

[0035] Fig.18 It is a graphic Fig.17 A plan view of the cover shown.

[0036] Fig.19 It is a graphic Fig.18 Perspective view of the cover (seen from the bottom).

[0037] Fig. 20 It is a graphic Figure 1 A partially cutaway perspective view of an exemplary battery after assembly.

[0038] Fig.21 is a flow chart illustrating an exemplary method for manufacturing a battery according to some embodiments. DETAILED DESCRIPTION

[0039] The description of the exemplary embodiments is intended to be read in conjunction with the accompanying drawings, which are considered a part of the entire written description. In the description, relative terms such as "below", "above", "horizontally", "vertically", "above", "below", "above", "below", "top", and "bottom" and their derivatives (e.g., "horizontally", "downwardly", "upwardly", etc.) should be understood to refer to the orientation as described subsequently or as shown in the drawings discussed. These relative terms are for convenience of description and do not require that the equipment be constructed or operated in a particular orientation. Terms such as "connected" and "interconnected" refer to a relationship between structures that is fixed or attached directly or indirectly through intermediate structures, which includes both removable and solid attachments or relationships, unless otherwise expressly stated.

[0040] For the convenience of the following description, it is to be understood that the embodiments described below may assume other variations and implementations. It should also be understood that the specific articles, compositions and / or processes described herein are merely exemplary and should not be considered limiting.

[0041] In the present disclosure, the singular forms "a", "an" and "the" include plural references, and references to a specific numerical value include at least the specific value, unless the context clearly indicates otherwise. When a numerical value is expressed in approximate form, i.e., using the prefix "about", it should be understood that the specific numerical value constitutes another embodiment. As used herein, "about X" (wherein X is a numerical value) preferably refers to ±10% (including the end value) of the value. For example, the phrase "about 8" preferably refers to a value between 7.2 and 8.8 (including the end value). Wherever a range appears, all ranges are inclusive and combinable. For example, when referring to a range of "1 to 5", the range referred to should be understood to include a range of "1 to 4", "1 to 3", "1 to 2", "1 to 2 and 4 to 5", "1 to 3 and 5", "2 to 5", etc. In addition, when a list of alternatives is explicitly provided, the list can be interpreted as meaning that any alternative may be excluded, for example, by a negative limitation in a claim. For example, when referring to a range of "1 to 5", the referenced range can be understood to include any case where any of 1, 2, 3, 4 or 5 is negatively excluded; thus, the reference of "1 to 5" can be understood as "1 and 3 to 5, but not including 2", or simply interpreted as "wherein 2 is not included". It is intended that any positively mentioned components, elements, attributes or steps can be explicitly excluded in the claims, regardless of whether these components, elements, attributes or steps are listed as alternatives or whether they are independently mentioned.

[0042] The term "substantially parallel" as used herein means that the deviation from parallelism is within 10° or less, such as within 5° or less. The term "substantially orthogonal" or "substantially perpendicular" as used herein means that the deviation from orthogonal or perpendicular is within 10° or less, such as within 5° or less.

[0043] The terms "positive electrode" and "negative electrode" used herein, such as "positive plate" and "negative plate", can be interchanged. In the exemplary battery described herein, the "negative plate" can be switched to the "positive plate", and the "positive plate" can also be switched to the "negative plate".

[0044] A lead-acid battery includes at least one cell having one or more positive plates and one or more negative plates made of lead or lead alloy plates. A lead oxide paste may be applied to the positive plates. A lead oxide paste with powdered sulfate added may be applied to the negative plates. A porous separator may be used to prevent the negative and positive plates from contacting each other but allow ions to move between them. Positive strips may be used to connect the positive plates in each cell together, while negative strips may be used to connect the negative plates in each cell together. Cell connectors may be used to join the positive strip of one cell to the negative strip of the next cell. An electrolyte such as a solution or gel containing sulfuric acid is used to promote the electrochemical reaction between the positive and negative plates in each cell.

[0045] The battery cells are enclosed in a battery case and covered with a cover. The battery case and cover may be made of a plastic material such as polypropylene. The terminal posts are configured to connect the battery to an object that requires power, such as an appliance, device, or circuit. The terminal posts carry current in and out of the battery—current flows in during charging and current flows out during discharging.

[0046] Lead-acid batteries may also include a current collector (CC) within each cell. The current collector is a bridging component that collects the current generated at the electrode and connects to the external circuit. The current collector can hold the active material on the electrode, strips, and terminal posts.

[0047] The terms "strip", "strip structure" and "strip layout" used herein are understood to cover a conductive structure that is disposed outside one or more cells and is connected to the tips of multiple anodes or multiple cathodes or multiple anodes and multiple cathodes. For example, a positive strip is used to connect the tips of multiple positive electrodes together. A negative strip is used to connect the tips of multiple negative electrodes together. In some embodiments, each electrode may be a plate with a tip. Each of the positive and negative strips may be cast as a whole and may have a notch on one side that matches the tip of the electrode. The strip structure as described herein may be a structure having a specific structure that is configured to connect the tips of multiple negative electrodes in a first cell on one side, connect the tips of multiple positive electrodes in a second cell on the opposite side, and also connect the tips of two series together. A cell connector may not be required. The strip, strip structure or strip layout may be made of a suitable material, such as lead, lead calcium tin, lead tin or other lead alloys. The strip, strip structure or strip layout may be considered to be part of a current collector or referred to as an electrode current collector. However, the strips, strip structures or strip arrangements described herein are distinct from current collectors used within electrochemical cells.

[0048] The current collector disposed within the electrochemical cell may be optional, and in certain embodiments, may be a grid structure. The grid made of lead or lead alloy material is configured to hold the positive or negative active material within the grid structure, carry the discharge current out of the active material and carry the charge current back into the active material. The grid may firmly hold the active material and resist the expansion forces generated during the electrochemical reaction, such as when the active material PbO2 is converted to PbSO4 in the positive grid and the active material Pb is converted to PbSO4 in the negative grid.

[0049] Unless otherwise expressly stated, the terms "battery" and "battery assembly" are used interchangeably, and the term "cell" used herein refers to an electrode group including a plurality of positive plates and a plurality of negative plates. As used herein, the term "electrochemical cell" refers to a subunit located between a positive plate and a negative plate. For ease of description, the terms "cell" and "electrochemical cell" are sometimes used interchangeably.

[0050] The ribbon structure may corrode during use, so it must minimize corrosion, maintain its shape, and maintain good adhesion to the electrode to prevent battery performance degradation. The ribbon structure must be able to withstand corrosion under conditions of elevated operating temperatures and long-term cycling.

[0051] The present disclosure provides a unique strip structure, a group of strip structures including the strip structure, a battery or battery assembly including the strip structure, and a method of manufacturing a battery or a battery assembly.

[0052] exist Figures 1 to 20 In the present invention, like items are represented by like reference numerals, and for the sake of brevity, the description of the structure provided above with reference to the aforementioned figures is not repeated. Figures 1 to 20 The exemplary structure described in Fig.21 The method described in .

[0053] Reference Figure 1 , illustrates an exemplary battery 100 according to some embodiments. Such a battery 100 may be a lead-acid battery, which is rechargeable in some embodiments. The exemplary battery 100 includes a housing 10 (or battery case), a plurality of battery cells 20 disposed in the housing 10, and a set of strip structures 45. Figure 7 The housing 10 may include an outer wall 12, a bottom wall 14, and a cell separator 16 for separating the housing 10 to accommodate the cell 20. The cell separator 16 may have one or two notches 15 formed thereon.

[0054] Each of the plurality of cells 20 includes a plurality of positive plates 22 and a plurality of negative plates 24. Each corresponding electrode plate has a corresponding tip. The positive plate 22 includes a tip 22a and a body 22b. The negative plate 24 includes a tip 24a and a body 24b. The electrode plates are labeled 25, and the corresponding tips are labeled 25a. Figures 8 to 10 , illustrates an exemplary battery cell 20. The battery cell 20 may include any suitable number of positive plates and negative plates. For example, Figures 8 to 10 As shown, the exemplary battery cell 20 includes five positive plates 22 and six negative plates 24. A separator 29 is disposed between the positive plates 22 and the negative plates 24.

[0055] The positive and negative plates may be made of any suitable material, which may be lead or a lead alloy, such as a lead-tin-calcium-aluminum alloy. The separator 29 may be an absorbent glass absorbent mat containing glass fibers. The housing 10 and cover 50 of the battery may be made of a plastic such as acrylonitrile-butadiene-styrene copolymer (ABS) or a polyolefin such as polypropylene.

[0056] The active material in the positive plate may be lead dioxide, and the active material in the negative plate may be metallic sponge lead. When the circuit is created, these substances react with sulfuric acid during charging and discharging according to the following chemical reaction: PbO2+Pb+2H2SO4=2PbSO4+2H2O. On the positive and negative plates, the following electrochemical reactions may occur:

[0057] Positive discharge:

[0058] Positive charging:

[0059] Negative discharge:

[0060] Negative charging:

[0061] Return to reference Figure 1 A group of strip structures 45 are disposed above the electrode plate 25 and connected to the tip 25 a of the electrode plate 25 . Fig.11 An exemplary set of strip structures is illustrated in FIG.

[0062] Reference Figure 1 and Fig.11 , a set of strip structures 25 includes one or more first strip structures 30 (or first type of strip structures). Fig.11 and Fig.12 As shown, the first strip structure 30 includes a positive strip line 31, a negative strip line 33 and at least two bridge lines 35, which are arranged between the positive strip line 31 and the negative strip line 33 and connected to the positive strip line 31 and the negative strip line 33. In the first strip structure 30, the positive strip line 31 and the negative strip line 33 are parallel or approximately parallel to each other. In some embodiments, at least two bridge lines 35 arranged between the positive strip line 31 and the negative strip line 33 are parallel or approximately parallel to each other. In some embodiments, at least two bridge lines 35 can be approximately perpendicular to the positive strip line 31 and the negative strip line 33. For illustrative purposes, two bridge lines 35 are shown in the accompanying drawings. The at least two bridge lines 35 can be any suitable number. For example, the first strip structure 30 can include two bridge lines 35, three bridge lines 35, or four bridge lines 35.

[0063] Reference Figure 11 to Figure 12 , the first stripe structure 30 may be in the shape of a number (or pound) sign ("#") having two sets of lines perpendicular to each other, or in the shape of a ladder. In some embodiments, the positive stripe lines 31 and the negative stripe lines 33 may have different lengths. Figure 11 to Figure 12 As shown, the positive electrode strip line 31 is shorter than the negative electrode strip line 33 because there are more negative electrode plates 24 than positive electrode plates 22 in each battery cell. Figure 1 , Figures 7 to 10 and Fig.13 As shown, each battery cell includes five positive plates 22 and six negative plates 24 .

[0064] Reference Figure 1 and Fig.13 The negative electrode strip line 33 in the first strip structure 30 is connected to the corresponding tips 24a of the plurality of negative electrode plates 24 in the first battery cell 20a. The positive electrode strip line 31 is connected to the corresponding tips 22a of the plurality of positive electrode plates 22 in the second battery cell 20b, and the second battery cell 20b is adjacent to and different from the first battery cell. The battery cell separator 16 ( Figure 7) is configured as a bridge line 35 in the first strip structure 30. The corresponding tip of the electrode plate is also called a plate ear, and the terms "tip" and "plate ear" can be used interchangeably in the present disclosure.

[0065] Optionally, each of the positive stripe line 31 and the negative stripe line 33 may have a notch (not shown) on their back side that is configured to cooperate with the electrode tip. For example, the negative stripe line 33 has a notch on one side that is configured to cooperate with the corresponding tips of the plurality of negative plates 24 in the first battery cell 20a. The positive stripe line 31 has a notch on one side that is configured to cooperate with the corresponding tips of the plurality of positive plates 22 in the second battery cell 20b. In addition, optionally, each of the positive stripe line 31 and the negative stripe line 33 may have a notch 37 on the front side, which may be used to define the physical boundaries of the plate ears.

[0066] Reference Figure 1 , Fig.11 and Fig.13 In some embodiments, a group of strip structures 45 further includes a second strip structure 32 and a third strip structure 34, wherein the second strip structure 32 is connected to a plurality of positive electrodes 22 in the starting cell 20a, and the third strip structure 34 is connected to a plurality of negative electrodes 24 in a terminating cell 20g. Fig.13 As shown, the exemplary battery includes six cells 20a to 20g. The second strip structure 32 is connected to the positive terminal post 82 ( Figure 1 The third strip structure 34 is connected to the negative terminal post 84 of the battery 100 .

[0067] In some embodiments, a set of strip structures 45 further includes a fourth strip structure 36, which is connected to corresponding tips of a plurality of negative plates 24 and a plurality of positive plates 22 from two adjacent cells. In some embodiments, each of the second strip structure 32, the third strip structure 34, and the fourth strip structure 36 may be in the shape of a straight strip. The length of the fourth strip structure 36 may be twice the length of the second strip structure 32 or the length of the third strip structure 34. Each of the second strip structure 32, the third strip structure 34, and the fourth strip structure 36 may also have a notch on the back side that matches the tip of the electrode plate (or plate ear).

[0068] The battery 100 may include any suitable number of cells. For example, in some embodiments, the battery includes six cells. A set of strip structures 45 includes four first type strip structures 30. The set of strip structures also includes one of each of the second strip structure 32, the third strip structure 34, and the fourth strip structure 36.

[0069] Reference Figure 1 and Fig.11In some embodiments, the fourth strap structure 36 is located at an end of the battery 100 that is opposite to one end of the positive terminal post 82 and the negative terminal post 84 .

[0070] Each of the plurality of strip structures is formed of a material selected from the group consisting of lead, lead calcium tin, lead tin or any combination thereof. The first strip structure is an integrally formed structure or an integrally cast structure and is not welded to the electrode plate.

[0071] Reference Figure 1 In addition to the terminal posts 80 (such as the positive terminal post 82 and the negative terminal post 84), the exemplary battery 100 also includes a cover 50, a venting structure 60, a top cover 70, and a cured encapsulant 40. The cured encapsulant 40 is made of a cross-linked polymer (such as an epoxy resin) and is disposed between the battery cell and the cover 50. The electrode plate tips and a set of strip structures 45 are embedded in the cured encapsulant 40.

[0072] Reference Figure 2 , Figure 3 and Figure 4 , a cross-sectional view of an exemplary battery 100 is shown. Figure 2 is along Figure 1 A cross-sectional view along the AA' direction is shown. Figure 3 is along Figure 1 A cross-sectional view along the BB' direction is shown. Figure 2 and Figure 3 The cross-sectional view in Figure 1 It is rotated 180 degrees to show the terminal post 80 on the left. Figure 4 yes Figure 3 The strip structure includes a first strip structure 30, a second strip structure 32 ( Figures 2 to 4 ), a third stripe structure 34 and a fourth stripe structure 36, which are connected to the electrode plates and embedded in the encapsulant 40, which is used to seal and bond the battery cells, the cover 50 and the top cover 70. The third stripe structure 34 is connected to the corresponding tips of the plurality of negative plates 24. The fourth stripe structure 36 is connected to the corresponding tips of the plurality of negative plates 24 and the plurality of positive plates 22 from two adjacent battery cells.

[0073] Reference Figures 5 and 6 , which illustrates a cross-sectional view of a portion of the battery 100. The second strip structure 32 is connected to the plurality of positive electrodes 22 in the starting cell and to the positive terminal post 82 ( Figure 1 ). The third strip structure 34 is connected to a plurality of negative electrodes 24 in a termination cell and to the negative terminal post 84 of the battery 100. Figures 5 and 6 As shown, the second strip structure 32 and the third strip structure 34 may each include a protruding portion for connecting with the terminal post 82 and the terminal post 84, respectively.

[0074] On the other hand, the present disclosure also provides a strip structure, such as the first strip structure 30 and a group of strip structures 45 described herein. Strip structures such as the first type of strip structure 30 described herein are in a group of strip structures configured to be arranged in a battery 100. In some embodiments, the battery 100 is a lead-acid battery. The battery 100 also includes a housing 10 and a plurality of battery cells 20 arranged in the housing 10. Each of the plurality of battery cells 20 includes a plurality of positive plates 22 and a plurality of negative plates 24. Each corresponding electrode plate has a corresponding tip. The first strip structure 30 includes a positive strip line 31, a negative strip line 33, and at least two bridge wires 35, and the at least two bridge wires 35 are arranged between the positive strip line 31 and the negative strip line 33 and connected to the positive strip line 31 and the negative strip line 33. The negative strip line 33 is configured to be connected to the corresponding tips of the plurality of negative plates 24 in the first battery cell. The positive electrode strip line 31 is configured to be connected to corresponding tips of the plurality of positive electrode plates 22 in a second battery cell, which is different from the first battery cell.

[0075] In some embodiments, the positive strip lines 31 and the negative strip lines 33 in the first strip structure 30 are parallel or approximately parallel to each other. The negative strip line 33 has a notch configured to cooperate with the corresponding tips of the plurality of negative plates 24 in the first battery cell. The positive strip line 31 has a notch configured to cooperate with the corresponding tips of the plurality of positive plates 22 in the second battery cell. In some embodiments, at least two bridge wires 35 arranged between the positive strip line 31 and the negative strip line 33 are parallel or approximately parallel to each other. The at least two bridge wires 35 can be two bridge wires, three bridge wires, or four bridge wires. Such a strip structure 30 is an integrally molded structure or an integrally cast structure, and includes a material selected from the group consisting of lead, lead-calcium-tin, lead-tin, or any combination thereof.

[0076] The first stripe structure 30 may be in the shape of a number (or pound) sign ("#") having two sets of lines perpendicular to each other, or in the shape of a ladder. In some embodiments, the positive stripe lines 31 and the negative stripe lines 33 may not have the same length.

[0077] Reference Fig.21 , an exemplary method 200 for forming a battery or battery assembly as described herein is provided.

[0078] At step 202, the set of strip structures 45 are assembled onto a plurality of cells 20. The resulting structure 38 is Fig.13 The negative electrode strip lines 33 in the first strip structure 30 are connected to the corresponding tips of the plurality of negative electrode plates 24 in the first battery cell 20a. The positive electrode strip lines 31 in the first strip structure 30 are connected to the corresponding tips of the plurality of positive electrode plates 22 in the second battery cell 20b.

[0079] In some embodiments, the battery is a lead-acid battery. The battery can include any suitable number of cells. In some embodiments, the battery includes six cells, and the set of strip structures includes four first strip structures 30. In the first strip structure 30, at least two bridge wires 35 disposed between the positive strip line 31 and the negative strip line 34 are parallel or substantially parallel to each other. The at least two bridge wires 35 include two bridge wires, three bridge wires, or four bridge wires.

[0080] In some embodiments, the group of strip structures 45 further includes a second strip structure 32 and a third strip structure 34. The step of assembling the group of strip structures onto a plurality of cells further includes: connecting the second strip structure 32 to a plurality of positive electrodes 22 in a starting cell; and connecting the third strip structure 34 to a plurality of negative electrodes 24 in a terminating cell. The group of strip structures 45 further includes a fourth strip structure 36. The step of assembling the group of strip structures onto a plurality of cells further includes: connecting corresponding tips of a plurality of negative plates 24 and a plurality of positive plates 22 from two adjacent cells.

[0081] At step 204, a set of strip structures and a plurality of cells are placed in a housing to form a partially assembled structure. The resulting structure 39 is Fig.14 and Fig.15 Picture. Fig.16 A top plan view of structure 39 is shown. Optionally, each stripe structure may have a notch 37. Notch 37 may be used only to define physical boundaries. In some embodiments, each stripe structure has no notch.

[0082] At step 206, the partially assembled structure 39 is inverted (ie, turned upside down) to contact the back side of the lid. The encapsulant 40 is dispensed onto the back side of the lid 50, which is also inverted. Fig.17 The structure of step 206 is shown. The encapsulant 40 is shown in its cured shape. Fig.17 In step 206, an encapsulant is dispensed in the form of a liquid or paste onto the back side of the cover 50, and the structure 39 and the encapsulant are placed together on top of the cover. Fig.18 yes Fig.17 A plan view of the cover is shown with strip structure 30 , strip structure 32 , strip structure 34 and strip structure 36 projected onto the view. Fig.19 It is a graphic Fig.1850. The exemplary cover 50 includes hollow support beams 56 and 57 and a vent structure 60. The cover 50 defines a hollow channel 52, which is configured to hold the potting agent 40 and ensure that the potting agent 40 flows evenly. The potting agent 40 seals the housing 10 and the cover 50. The strip structure 45 is immersed in the potting agent 40 above the cover, and the cover is also wrapped by the potting agent 40. The potting agent 40 can be any suitable polymer material, such as epoxy resin. Fig.19 , the channel 52 with the encapsulant 40 accommodates the strip structure 45 including the strip structure 30, the strip structure 32, the strip structure 34 and the strip structure 36. The bridge wire 35 from the strip structure 30 is also fitted between the hollow support beams 57. The hollow support beams 56 and the hollow support beams 57 can match the battery cell separator 16 so that the battery cell and the cover are fixed in the correct position and will not shift. Therefore, the battery stability is good.

[0083] At step 208, after the components are assembled, the encapsulant 40 is cured to form the resulting battery 100. Fig. 20 It is a graphic Figure 1 The cell separator 16 separates the cells including the electrode plates 25 such as the positive plate 22 and the negative plate 24. The cell separator 16 may also define a notch 15 for mating with the bridge wire 35 in the first strip structure 30.

[0084] A group of strip structures including the first type of strip structure as described herein and the resulting battery have many advantages. For example, each strip structure is cast or molded as a whole. Compared with the L-shaped through-wall welding process used in the prior art, the positive and negative electrodes need to be connected by wall welding, and the amount of lead or lead alloy used here is reduced. In comparison, in the current L-shaped through-wall welding process, the positive and negative electrodes need to be connected through the wall or connected to the wall. The bonding may not be strong enough. An additional welding process is required. The welding points are easily corroded by acids such as sulfuric acid used in the battery cells.

[0085] Since no welding process is used, the method described in this article eliminates the defect rate caused by the through-wall welding process and provides a more stable positive and negative electrode connection. The one-piece casting technology used in this article reduces the internal resistance of the connection and the battery, which can meet the requirements of higher power discharge. The design of the strip structure significantly improves the corrosion resistance of the strip structure and the resulting battery. The stability and durability are greatly improved. In addition, even if a part corrodes, such as a bridge wire breaks due to corrosion, the overall performance of the battery will not be significantly affected. The resulting battery can be used in vehicles, golf carts, or any other application. The battery can be rechargeable.

[0086] Although the subject matter has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be interpreted broadly to encompass other variants and embodiments that may occur to a skilled artisan.

Claims

1. A battery comprising: case; A plurality of battery cells, the plurality of battery cells being disposed in the housing, wherein each of the plurality of battery cells comprises a plurality of positive electrode plates and a plurality of negative electrode plates, and each corresponding electrode plate has a corresponding tip; as well as A group of strip structures, the group of strip structures includes one or more first strip structures, the first strip structure includes a positive strip line, a negative strip line and at least two bridge lines, the at least two bridge lines are arranged between the positive strip line and the negative strip line and connected to the positive strip line and the negative strip line, the negative strip line is connected to the corresponding tips of multiple negative plates in a first battery cell, the positive strip line is connected to the corresponding tips of multiple positive plates in a second battery cell, and the second battery cell is different from the first battery cell.

2. The battery according to claim 1, wherein The battery is a lead-acid battery.

3. The battery according to claim 1, wherein The positive strip lines and the negative strip lines in the first strip structure are parallel or substantially parallel to each other.

4. The battery according to claim 1, wherein The positive strip line has a notch on one side configured to mate with the corresponding tips of the plurality of negative plates in the first battery cell, and the positive strip line has a notch on one side configured to mate with the corresponding tips of the plurality of positive plates in the second battery cell.

5. The battery according to claim 1, wherein The at least two bridge lines disposed between the positive strip line and the negative strip line are parallel or substantially parallel to each other.

6. The battery according to claim 1, wherein The at least two bridge lines include two bridge lines, three bridge lines or four bridge lines.

7. The battery according to claim 1, wherein The group of strip structures also includes a second strip structure and a third strip structure, the second strip structure is connected to multiple positive electrodes in a starting battery cell, and the third strip structure is connected to multiple negative electrodes in a terminating battery cell, wherein the second strip structure is connected to the positive terminal column of the battery, and the third strip structure is connected to the negative terminal column of the battery.

8. The battery according to claim 7, wherein The set of strip structures further includes a fourth strip structure connected to corresponding tips of a plurality of negative plates and a plurality of positive plates from two adjacent battery cells.

9. The battery according to claim 8, wherein The fourth strip structure is located at an end of the battery opposite to one end of the positive terminal post and the negative terminal post of the battery.

10. The battery according to claim 1, wherein Each of the set of strip structures is formed of a material selected from the group consisting of lead, lead calcium tin, lead tin, or any combination thereof.

11. The battery according to claim 1, wherein The first strip structure is an integrally formed structure.

12. The battery according to claim 1, wherein The plurality of battery cells is six battery cells, and the group of strip structures includes four of the first strip structures.

13. A strip structure in a set of strip structures, the set of strip structures being configured to be arranged in a battery, the battery comprising a housing and a plurality of cells arranged in the housing, wherein: Each of the plurality of battery cells includes a plurality of positive plates and a plurality of negative plates, and each corresponding electrode plate has a corresponding tip, and the strip structure includes: Positive strip line; Negative strip line; and At least two bridging wires are arranged between the positive strip line and the negative strip line and connected to the positive strip line and the negative strip line, the negative strip line is configured to connect to the corresponding tips of multiple negative plates in a first battery cell, and the positive strip line is configured to connect to the corresponding tips of multiple positive plates in a second battery cell, and the second battery cell is different from the first battery cell.

14. The strip structure according to claim 13, wherein: The positive strip lines and the negative strip lines in the strip structure are parallel or substantially parallel to each other.

15. The strip structure according to claim 13, wherein: The positive strip line has a notch on one side configured to mate with the corresponding tips of the plurality of negative plates in the first battery cell, and the positive strip line has a notch on one side configured to mate with the corresponding tips of the plurality of positive plates in the second battery cell.

16. The strip structure according to claim 13, wherein: The at least two bridge lines disposed between the positive strip line and the negative strip line are parallel or substantially parallel to each other.

17. The strip structure according to claim 13, wherein: The at least two bridge lines include two bridge lines, three bridge lines or four bridge lines.

18. The strip structure according to claim 13, wherein: The strip structure is an integrally formed structure and includes a material selected from the group consisting of lead, lead-calcium-tin, lead-tin, or any combination thereof.

19. A method for forming a battery according to claim 1, comprising the steps of: Assembling the set of strip structures onto the plurality of battery cells, the step of assembling the set of strip structures onto the plurality of battery cells comprising: connecting the negative electrode strip lines in the first strip structure to corresponding tips of a plurality of negative electrode plates in the first battery cell; and connecting the positive strip lines in the first strip structure to corresponding tips of a plurality of positive plates in a second battery cell, the second battery cell being different from the first battery cell; placing the set of strip structures and the plurality of cells within the housing to form a partially assembled structure; inverting the partially assembled structure to contact a back side of the cover, wherein encapsulant is dispensed onto the back side of the cover; and The encapsulant is cured to provide the battery.

20. The method according to claim 19, wherein: The battery is a lead-acid battery having six cells, and the set of strip structures includes four of the first strip structures.

21. The method according to claim 19, wherein: The at least two bridge lines disposed between the positive strip line and the negative strip line are parallel or substantially parallel to each other.

22. The method according to claim 19, wherein: The at least two bridge lines include two bridge lines, three bridge lines or four bridge lines.

23. The method according to claim 19, wherein: The set of strip structures further includes a second strip structure and a third strip structure, and the step of assembling the set of strip structures onto the plurality of battery cells further includes: connecting the second strip structure to a plurality of positive electrodes in the starting battery cell; and The third strip structure is connected to a plurality of negative electrodes in a termination cell.

24. The method according to claim 23, wherein: The set of strip structures further includes a fourth strip structure, and the step of assembling the set of strip structures onto the plurality of battery cells further includes: The corresponding tips of the plurality of negative plates and the plurality of positive plates from two adjacent battery cells are connected.

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