Battery unit terminal alignment fixing device

Abstract

According to one aspect of the present invention, there is provided a battery cell terminal alignment fixture for aligning protruding terminals of a plurality of battery cells. The fixture includes a first alignment member including a plurality of first terminal holes and a plurality of respective and associated first engagement surfaces, and a second alignment member including a plurality of second terminal holes and a plurality of respective and associated second engagement surfaces. The corresponding first and second terminal holes are configured to collectively receive corresponding battery cell terminals. The first alignment member and the second alignment member are connected together in a sliding relationship such that sliding of one of the first alignment member or the second alignment member relative to the other causes the respective first and second engagement surfaces to be closer, therefore, the corresponding battery cell terminal is clamped between the first joint surface and the second joint surface.

Description

Technical Field

[0001] The present invention relates to battery technology, and more particularly to a battery cell terminal alignment fixture, a battery including such an alignment fixture (calibration fixture), and an electric hot water system including such an alignment fixture or battery. Background Art

[0002] The growing interest in using renewable energy sources instead of fossil fuels has led to the development of many new electrical products. For example, cars, trains, heating systems and household products can all be powered by electricity. In some cases, it may be advantageous for an electrical product to be at least partially powered by batteries. Larger capacity batteries usually consist of multiple cells that are electrically connected to each other in some way.

[0003] Each cell may include one or more cell terminals extending from the body of the cell. This terminal is configured to facilitate electrical connection between the cell and other components. Therefore, the cell terminals are typically made of a material with high conductivity (e.g., copper or aluminum). However, such materials are typically highly ductile, and in some cases, the cell terminals may bend or twist due to minimal contact during their manufacture and / or transportation. These battery cells (especially the cell terminals) may therefore lack uniformity, with significant differences in the orientation and position of the cell terminals. In the process of assembling a battery comprising multiple cells, such variations can result in severe misalignment between the cell terminals and the components to be connected.

[0004] Misalignment of cell terminals can be a problem when connections are made between cell terminals and other components, such as using laser or ultrasonic welding. Misalignment is particularly problematic when connections are made using automated manufacturing equipment, as the terminals may not be positioned within the tolerances of the components being connected. For such assembly operations, manually adjusting multiple cell terminals to the correct position is both time-consuming and inefficient.

[0005] The present invention has been developed in this context. Summary of the invention

[0006] According to one aspect of the present invention, a battery cell terminal alignment fixture for aligning protruding terminals of a plurality of battery cells is provided. The fixture comprises a first alignment component and a second alignment component, the first alignment component comprising a plurality of first terminal holes and a corresponding plurality of associated first engagement surfaces, and the second alignment component comprising a plurality of second terminal holes and a corresponding plurality of associated second engagement surfaces. The corresponding first terminal holes and second terminal holes are configured to receive the corresponding cell terminals together. The first alignment component and the second alignment component are connected together in a sliding relationship, so that one of the first alignment component or the second alignment component slides relative to the other, thereby bringing the corresponding first engagement surface and the second engagement surface closer, thereby clamping the corresponding battery cell terminal between the first engagement surface and the second engagement surface. Therefore, the corresponding battery cell terminal can be clamped between the first engagement surface and the second engagement surface at a predetermined controlled position. Therefore, the battery cell terminal alignment fixture can be used to accurately position the corresponding terminals of a plurality of battery cells, both in a general sense and relative to each other (i.e., relative to adjacent battery cell terminals).

[0007] In particular, the cell terminal alignment fixture is configured to receive (i.e., gather) a plurality of differently positioned and oriented battery cell terminals in the corresponding first terminal holes and second terminal holes when in use, and to align these terminals in an accurate and repeatable manner. The sizes of the corresponding pairs of first terminal holes and second terminal holes are preferably designed to receive the corresponding cell terminals with a large tolerance in the actual position and orientation of the cell terminals. The sliding relationship between the first alignment member and the second alignment member facilitates gathering each corresponding cell terminal in the first terminal hole and the second terminal hole, regardless of their initial position and orientation. The corresponding first engagement surface and the second engagement surface are brought closer together to move each cell terminal to a specific predetermined position in a repeatable manner.

[0008] In some examples, the battery cell terminal alignment fixture may also include a plurality of interconnecting strips mounted in the second alignment member. Each second engagement surface may be at least partially defined by a corresponding interconnecting strip. Thus, the first alignment member and the second alignment member may be connected together in a sliding relationship so that when in use, one of the first alignment member or the second alignment member slides relative to the other, bringing the first engagement surface closer to the interconnecting strip defining the second engagement surface, so that the corresponding battery cell terminal contacts the corresponding interconnecting strip. These interconnecting strips are preferably formed of a conductive material so that when in use, the cell terminal contacts the interconnecting strip, forming an electrical connection between the corresponding cell terminal and the interconnecting strip.

[0009] Furthermore, in some examples, each second engagement surface may be completely defined by the interconnecting strip. This advantageously provides the largest possible surface area to ensure that a reliable electrical connection can be formed between the battery cell terminal and the corresponding interconnecting strip when in use.

[0010] Mounting the interconnect strips in the second alignment feature advantageously maintains the positions of the interconnect strips relative to each other and the cell terminals. Since the interconnect strips are retained in the second alignment feature, the risk of accidental electrical contact (i.e., short circuit) between the interconnect strips and / or the cell terminals is minimized, particularly in examples where the second alignment feature is formed of an electrically insulating material.

[0011] In some examples, each first engagement surface can be defined by a corresponding protrusion extending into a corresponding second terminal hole of the second alignment member. Thus, the first engagement surface can be arranged directly opposite the second engagement surface so that the corresponding battery cell terminal can be clamped between the two directly opposite surfaces.

[0012] In some examples, each first engaging surface may include an access opening that facilitates access to a side of a corresponding battery cell terminal engaged with the first engaging surface when in use. The access opening may be a hole, a slot, a gap, or any other opening in the first engaging surface that facilitates access to the corresponding battery cell terminal through the first engaging surface. In particular, the access opening may advantageously facilitate access to the corresponding battery cell terminal for welding. For example, in some examples where the second engaging surface is at least partially defined by a conductive interconnect bar, the access opening may facilitate access to the battery cell terminal to weld the terminal to the interconnect bar. Examples of welding to form an electrical connection between a cell terminal and an interconnect bar may include laser welding and / or ultrasonic welding.

[0013] In some examples, each first engagement surface may be defined by a plurality of spaced apart protrusions. Thus, in such examples, the first engagement surface may be defined by a plurality of coplanar partial first engagement surfaces that simultaneously engage one side of the corresponding battery cell terminal when in use. It should be understood that in such examples, the access opening may be defined between the plurality of spaced apart protrusions that define the first engagement surface.

[0014] In some examples, the first alignment component can define a row of first terminal holes and a row of corresponding and associated first engagement surfaces. It can be seen that the second alignment component can define a row of second terminal holes and a row of corresponding and associated second engagement surfaces. With this arrangement, multiple individual battery terminals each received in a corresponding first terminal hole and second terminal hole can be aligned by a single relative sliding movement between the first alignment component and the second alignment component.

[0015] In some examples, the first alignment component can define multiple rows of first terminal holes and multiple rows of corresponding and associated first engagement surfaces. It can be seen that the second alignment component can define multiple rows of second terminal holes and multiple rows of associated second engagement surfaces. In some preferred examples, the first terminal holes and the associated first engagement surfaces can therefore be arranged in multiple rows and columns to define an array or matrix of first terminal holes and associated first engagement surfaces. Similarly, in some preferred examples, the second terminal holes and the associated second engagement surfaces can therefore be arranged in multiple rows and columns to define an array or matrix of second terminal holes and associated second engagement surfaces. Multiple rows of corresponding first terminal holes and second terminal holes facilitate simple alignment of many battery terminals through a single relative sliding movement between the first alignment component and the second alignment component.

[0016] In some examples, each pair of corresponding first and second engagement surfaces can be parallel to each other. This configuration can help ensure that when in use, when one of the first alignment member or the second alignment member moves relative to the other, the corresponding battery cell terminal can engage, i.e., contact, as many corresponding engagement surfaces as possible.

[0017] In some examples, the first alignment member and the second alignment member can be connected together and constrained relative to each other so that the sliding relationship is limited to a generally linear sliding along a sliding axis. By limiting the relative movement of the first alignment member and the second alignment member to linear movement, the alignment of the battery terminals in the corresponding first terminal holes and the second terminal holes can be simplified. The simplicity of relative movement between the first alignment member and the second alignment member can also improve the life of the alignment fixture. In addition, the linear sliding relationship means that the distance between the corresponding first engagement surface and the second engagement surface increases and / or decreases at the same rate across the corresponding surfaces. Therefore, this also improves the ability of the alignment member to engage with the corresponding battery cell terminal.

[0018] In some examples, the first engagement surface and the second engagement surface can be substantially perpendicular to the sliding axis. Thus, the force applied to achieve relative sliding movement between the first alignment member and the second alignment member can be directed substantially perpendicular to the engagement surfaces, thereby promoting particularly secure engagement of the respective battery cell terminals between the engagement surfaces when in use.

[0019] In some examples, the first alignment member and the second alignment member may be formed of an electrically insulating material. For example, the first alignment member and the second alignment member may be plastic members. As previously described, when in use, the alignment fixture may be used to align the terminals of a plurality of battery cells, and each cell terminal may be received in a corresponding pair of corresponding first terminal holes and second terminal holes. Therefore, since the cell terminals are separated from each other by the electrically insulating alignment member, the alignment fixture may advantageously reduce the risk of short circuits between the cell terminals.

[0020] Furthermore, in some preferred examples, the first engagement surface may be electrically insulating. As previously described, in some examples, the second engagement surface may be defined by a conductive interconnection strip. Thus, in use, the electrically insulating first engagement surface may clamp the corresponding battery cell terminal to the corresponding interconnection strip while minimizing the risk of short circuits.

[0021] In some examples, the battery cell terminal alignment fixture may also include a fixing means for fixing the first alignment component and the second alignment component in an appropriate position relative to each other. The fixing means can be used to fix the relative positions of these components after the first alignment component and the second alignment component are slid to cause the corresponding first engagement surface and the second engagement surface to move the corresponding battery cell terminal to the alignment position. Therefore, the fixing means can clamp the corresponding battery cell terminal between a pair of corresponding first engagement surfaces and the second engagement surface for any desired period of time. In some preferred examples, the fixing means may include a releasable or removable fixing means. In this way, the releasable fixing means can facilitate the rearrangement of the first alignment component and the second alignment component.

[0022] In another aspect of the present invention, a battery is provided, which includes a plurality of battery cells and a battery cell terminal alignment fixture as described in the examples herein. Each battery cell includes at least one battery cell terminal, and the terminal of each cell is arranged in a first terminal hole, in a corresponding second terminal hole, and between a first engagement surface and a corresponding second engagement surface.

[0023] In some examples of batteries, the battery cell terminal alignment fixture may include a plurality of interconnecting bars mounted in the second alignment component, and each second engagement surface may be at least partially defined by a corresponding interconnecting bar. In such an example, each cell terminal arranged in a corresponding second terminal hole may be electrically connected to an interconnecting bar defining an associated second engagement surface. Thus, the alignment fixture may form an electrical connection between the battery cell terminal and the corresponding interconnecting bar. As previously described, in particular, the alignment fixture may hold the cell terminal on or clamp it on the corresponding interconnecting bar.

[0024] In some examples, each battery cell may include a positive battery cell terminal and a negative battery cell terminal. The positive battery cell terminal and the negative battery cell terminal may both protrude from the same side of the corresponding battery cell. In some preferred examples, the battery cells may be arranged in a substantially similar orientation in the battery so that all of the battery cell terminals are arranged on the same side of the battery. Thus, in some examples, all of the battery cell terminals may be aligned using the same battery cell terminal alignment fixture described in any of the examples herein.

[0025] In such an example, and where the alignment fixture includes a plurality of interconnecting bars mounted in the second alignment component, the interconnecting bars can be configured to electrically connect the positive terminal of one cell with the negative terminal of another cell. Thus, the alignment fixture can be configured to electrically connect the plurality of cells in series. Alternatively, the interconnecting bars can be configured to electrically connect the positive terminal of one cell with the positive terminal of another cell, and to electrically connect the negative terminal of one cell with the negative terminal of another cell. Thus, the alignment fixture can be configured to electrically connect the plurality of cells in parallel.

[0026] In some other examples, each battery cell may include a positive battery cell terminal and a negative battery cell terminal, and the positive battery cell terminal and the negative battery cell terminal may each protrude from different sides of the corresponding battery cell. In some preferred examples, the positive terminal and the negative terminal may protrude from opposite sides of the corresponding cell. This may be advantageous for the manufacture and assembly of the battery.

[0027] In some examples where the battery includes cells having cell terminals extending from different sides of the respective cells, the battery cells may be alternately oriented such that the battery includes a plurality of positive and negative cell terminals protruding on a first side and a second side of the battery. The alignment fixture may be disposed on a first side of the battery and may include a plurality of interconnecting bars mounted in a second alignment component. The interconnecting bars may be configured to electrically connect the positive terminal of one cell to the negative terminal of another cell. In such examples, the alignment fixture may therefore be configured to electrically connect the plurality of cells in series. In some examples, the second alignment fixture may be disposed on a second side of the battery and may include a plurality of interconnecting bars mounted in a second alignment component thereof. The interconnecting bars may be configured to electrically connect the negative terminal of one cell to the positive terminal of another cell for series connection.

[0028] In some other examples where the battery includes cells having cell terminals extending from different sides of the respective cells, the battery cells may be arranged in the battery in substantially the same orientation. Thus, all positive terminals may protrude from a first side of the battery and all negative cell terminals may protrude from a second side of the battery. The alignment fixture may be arranged on a first side of the battery and may include a plurality of interconnecting bars mounted in a second alignment component. The interconnecting bars may be configured to electrically connect the positive terminal of one cell to the positive terminal of another cell. In such examples, the alignment fixture may therefore be configured to electrically connect multiple cells in parallel. In some such examples, the battery may include a second alignment fixture arranged on a second side of the battery and include a plurality of interconnecting bars mounted in a second alignment component thereof. The interconnecting bars may be configured to electrically connect the negative terminal of one cell to the negative terminal of another cell.

[0029] As described in the examples given above, where interconnecting strips are included, in different examples, the interconnecting strips of the alignment fixture may perform different functions. For example, each interconnecting strip may electrically connect the positive battery cell terminal of a battery cell to the negative battery cell terminal of a different battery cell. Thus, in some examples, the battery cells in the battery may be electrically connected to each other in series. Alternatively, in other examples, each interconnecting strip may electrically connect the positive battery cell terminal of a battery cell to the positive battery cell terminal of a different battery cell, or may connect the negative battery cell terminal of a battery cell to the negative battery cell terminal of a different battery cell. Thus, in some examples, the battery cells in the battery may be electrically connected to each other in parallel.

[0030] In some examples, each interconnect bar may include a connection pin. The battery may also include a battery management control board that is electrically connected to each interconnect bar via a corresponding connection pin. In some examples, the control board may be operated to change the voltage on each interconnect bar and, therefore, the voltage on each cell in the battery.

[0031] In some examples, each battery cell terminal arranged in the first terminal hole and the second terminal hole of the battery cell terminal alignment fixture can be arranged in its own first terminal hole and corresponding second terminal hole, respectively. In some examples, this may help reduce the risk of unwanted electrical contact between terminals of different cells.

[0032] In some other examples, the corresponding first terminal hole and the second terminal hole of the alignment fixture can be configured to receive a plurality of cell terminals together. Therefore, each battery cell terminal arranged in the first terminal hole and the second terminal hole of the battery cell terminal alignment fixture can be arranged in the corresponding first terminal hole and the second terminal hole together with one or more other battery cell terminals. Thus, in some examples, the battery may include a positive cell terminal, which is received in the same first terminal hole and the second terminal hole as the positive cell terminal of a different cell. In some examples, the battery may include a negative cell terminal, which is received in the same first terminal hole and the second terminal hole as the negative cell terminal of a different cell. In some examples, the battery may include a positive cell terminal, which is received in the same first terminal hole and the second terminal hole as the negative cell terminal of a different cell.

[0033] In an example including a plurality of unit terminals received in corresponding first and second terminal holes, an electrical connection can be formed between the terminals in the corresponding first and second terminal holes when in use. For example, such an electrical connection can be formed by sliding one of the first alignment member or the second alignment member relative to the other so as to bring the corresponding first and second engagement surfaces closer together to engage the unit terminals in the corresponding first and second terminal holes and bring the terminals into electrical contact with each other. It can be seen that in some examples, an electrical connection can be formed between a plurality of unit terminals without using an interconnect bar to connect the terminals.

[0034] In some examples, the battery may further include a cell housing defining a plurality of cell compartments. Each battery cell may be arranged in a cell compartment so that the batteries are held in position relative to each other. In some preferred embodiments, each cell may be located in its respective cell compartment, respectively. Thus, in some examples, each cell compartment may include a single cell. The cell compartments defined by the cell housing are advantageous for organizing and aligning the cells, facilitating faster and more efficient connection of the cell terminals using alignment fixtures during battery manufacturing.

[0035] In some examples, the cell compartments of the cell housing can be defined as a stacked structure. In other words, each cell compartment can be adjacent to (above or below) at least one other cell compartment of the cell housing. The stacked structure can save space while still facilitating efficient heat transfer between the cell compartments and the cooling conduit. In addition, this configuration can help to keep the cells in a particularly advantageous arrangement so that the corresponding cell terminals can be aligned simultaneously using an alignment fixture.

[0036] In some examples, the unit housing may further define a cooling conduit that is thermally coupled to the unit compartment. Each unit compartment may be thermally coupled to the cooling conduit directly (e.g., if the unit compartment and the cooling conduit are defined by a single integral component), or indirectly thermally coupled to the cooling conduit through a separate conductive component. When used, placing a unit separately in its own unit compartment may be particularly effective for transferring heat from the unit to the cooling conduit.

[0037] The term "thermally coupled" should be understood to refer to the facilities for transferring heat between the unit compartment and the cooling tubes of the unit housing. Conversely, for the context, if a component is thermally insulated, it is not thermally coupled to another component. For example, such a thermally insulated component may be separated from the other component by an insulating material.

[0038] In some examples, the battery cell terminal alignment fixture can be attached to the cell housing. In addition, in some examples, at least one of the first alignment component or the second alignment component can slide relative to the cell housing. Therefore, when the cell is held in place in the cell housing, one alignment component can move relative to the other alignment component and the cell housing so that the cell terminal engages between the corresponding first engagement surface and the second engagement surface, thereby facilitating the alignment of the terminals. In some preferred examples, both the first alignment component and the second alignment component can slide relative to the cell housing.

[0039] It can be seen that, in some preferred examples, the first alignment component and / or the second alignment component can slide linearly relative to each other and the unit housing along the sliding axis.

[0040] In another aspect of the present invention, an electric water heating system is provided, comprising a battery cell terminal alignment fixture according to any example described herein.

[0041] In another aspect of the present invention, an electric hot water system is provided, comprising a battery according to any example described herein. The electric hot water system may further comprise an electric heater for heating water. The battery may be electrically connected to the electric heater to supply power to the electric heater. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Several embodiments of the present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0043] Figure 1 is a schematic perspective view of a battery cell terminal alignment fixture;

[0044] Figure 2a is a schematic perspective view of the back side of a first alignment component of a battery cell terminal alignment fixture;

[0045] Figure 2b is a schematic perspective view of the back side of a second alignment component of a battery cell terminal alignment fixture;

[0046] Figure 3 is a schematic perspective view of a battery including a plurality of cells and a battery cell terminal alignment fixture;

[0047] Figure 4a is a schematic cross-sectional side view of a battery and an alignment fixture;

[0048] Figure 4b is a schematic close-up view of the terminal holes of the alignment fixture;

[0049] Figure 5a is a schematic perspective view of a unit housing holding a plurality of units; and

[0050] Figure 5b is a schematic perspective view of an example of a battery including a unit case. DETAILED DESCRIPTION

[0051] Figure 1 1 is a schematic perspective view of a battery cell terminal alignment fixture 10, which is used to align a plurality of battery cells 14 (eg Figure 3 As described in more detail below, such alignment fixture 10 advantageously facilitates simultaneous alignment of multiple cell terminals, for example, during manufacture and assembly of battery 16. Figures 3 to 5b A battery 16 including a plurality of cells 14 and a cell terminal alignment fixture 10 is shown, but reference will first be made to Figure 1 to Figure 2b , Figure 1 to Figure 2b The alignment fixture 10 itself is illustrated in more detail.

[0052] like Figure 1 As shown, the battery cell terminal alignment fixture 10 includes a first alignment component 18a and a second alignment component 18b. Figure 2a As more clearly shown in FIG. 1 , which shows a schematic rear perspective view, the first alignment member 18a has a plurality of first terminal holes 20a associated with corresponding first engagement surfaces 22a. Figure 2bAs more clearly shown in the rear perspective view of the battery 16, the second alignment member 18b has a plurality of second terminal apertures 20b associated with corresponding second engagement surfaces 22b. The second terminal apertures 20b and the associated second engagement surfaces 22b correspond to the corresponding first terminal apertures 20a and engagement surfaces 22a. As will be described in more detail later with reference to the remaining figures, each set of corresponding first terminal apertures 20a and second terminal apertures 20b is configured to receive a battery cell terminal 12. Thus, when the battery 16 is assembled, the terminals 12 of the plurality of cells 14 can be inserted into the corresponding first terminal apertures 20a and second terminal apertures 20b (e.g., Figure 3 shown).

[0053] The first alignment member 18a and the second alignment member 18b are connected together in a sliding relationship, that is, one of the alignment members 18a, 18b can slide relative to the other. As described in more detail later, the sliding relationship between the first alignment member 18a and the second alignment member 18b helps to capture or gather the unit terminal 12 between the first engagement surface 22a and the second engagement surface 22b, and subsequently bring the unit terminal 12 into an aligned position, even if the unit terminal 12 is initially misaligned or bent out of position.

[0054] Still refer to Figure 1 to Figure 2b In some examples, the first alignment feature 18a can define a row of first terminal holes 20a and associated first engagement surfaces 22a, and similarly, the second alignment feature 18b can define a corresponding row of second terminal holes 20b and associated second engagement surfaces 22b. Figure 1 to Figure 2b As shown in the example of, in some examples, the first alignment member 18a and the second alignment member 18b can each define a plurality of rows of corresponding first terminal holes 20a and second terminal holes 20b. Therefore, each alignment member 18a, 18b can have a matrix or grid of terminal holes 20a, 20b and associated engagement surfaces 22a, 22b, so that the terminals 12 of many units 14 can be aligned simultaneously by a simple relative sliding movement between the two alignment members 18a, 18b.

[0055] like Figure 1 and Figure 2aAs shown, in some preferred examples, each first engagement surface 22a of the first alignment component 18a can be defined by a corresponding protrusion 24. These protrusions 24 preferably extend (i.e., protrude) from a generally flat face of the first alignment component 18a (e.g., from a sliding surface 26), and the second alignment component 18b can slide against the sliding surface 26. As the first alignment component 18a and the second alignment component 18b are assembled together in the alignment fixture 10, the protrusions 24 defining the first engagement surface 22a can extend into the corresponding second terminal hole 20b associated with the corresponding second engagement surface 22b. In some examples, this enables the arrangement of the engagement surfaces 22a, 22b to be generally directly opposite to each other. In addition, as will be further referenced later Figure 4b In more detail, in some examples, each first engagement surface 22a may be defined by a plurality of spaced-apart protrusions 24, as shown in FIG. Figure 2a Thus, the first engaging surface 22a may include an access opening 28 that allows access to the corresponding cell terminal 12 engaged with the first engaging surface 22a.

[0056] Special reference Figure 2b , the alignment fixture 10 may also include a plurality of interconnecting bars 30 mounted in the second alignment feature 18b. Where the interconnecting bars 30 are included, the interconnecting bars 30 are preferably mounted in the second alignment feature 18b such that each second engagement surface 22b is at least partially defined by a corresponding interconnecting bar 30. Thus, engagement of the cell terminal 12 with the second engagement surface 22b in use results in contact between the cell terminal 12 and the corresponding interconnecting bar 30. In particular, the interconnecting bars 30 may be formed of a conductive material such that an electrical connection may be formed when the second engagement surface 22b is in contact with the cell terminal 12. The interconnecting bars 30 may electrically connect the terminals 12 of different cells 14 in the battery 16, as described in more detail later.

[0057] Now refer to Figure 3 , which shows a schematic perspective view of a battery 16, which includes an example of the cell terminal alignment fixture 10 described above. The battery 16 includes a plurality of cells 14, each cell having at least one battery cell terminal 12. For example, Figure 3 As shown, each of these cells 14 may include two terminals 12, such as a positive terminal 12a and a negative terminal 12b. An alignment fixture 10 is included in the battery 16 to align the cell terminals 12. Thus, the terminal 12 of each cell 14 is arranged in the first terminal hole 20a, in the corresponding second terminal hole 20b, and between the first engagement surface 22a and the corresponding second engagement surface 22b.

[0058] exist Figure 3In the battery 16 shown by way of example in FIG. 1 , each battery cell 14 includes a positive terminal 12a and a negative terminal 12b, both of which extend from the same side of the corresponding battery cell 14. In such an example, if an interconnect bar 30 is also included, the interconnect bar 30 can be configured to connect the cells 14 in series (i.e., by electrically connecting the negative terminal 12b of the cell 14 to the positive terminal 12a of a different cell 14) or in parallel (i.e., by electrically connecting the negative terminal 12b of a different cell 14 or the positive terminal 12a of a different cell 14, respectively). In a preferred example, the first alignment feature 18a and the second alignment feature 18b can be formed of an electrically insulating material (e.g., plastic) to minimize the risk of short circuits and ensure that electricity is conducted only along a desired route (e.g., a route defined by the interconnect bar 30 when the interconnect bar 30 is included).

[0059] Still refer to Figure 3 In some examples, the corresponding pair of first terminal holes 20a and second terminal holes 20b can each receive a single cell terminal 12. In other words, each battery cell terminal 12 can be arranged in its own first terminal hole 20a and corresponding second terminal hole 20b, respectively. This is beneficial for the alignment of the cell terminals 12, and can also reduce the risk of undesired electrical contact (i.e., short circuit) between the terminals 12 of the cells 14 in the battery 16.

[0060] Figure 4a Shown throughout Figure 3 Schematic cross-sectional view of a portion of a battery 16 at centerline AA. The cross-sectional view shows the alignment fixture 10 disposed with a battery cell 14 having terminals 12 extending through terminal apertures 20a, 20b defined by first and second alignment features 18a, 18b as previously described.

[0061] exist Figure 4a The result or effect of the sliding relationship between the first alignment member 18a and the second alignment member 18b is clearly shown in the example of FIG. As described above, sliding one of the first alignment member 18a or the second alignment member 18b relative to the other brings the corresponding first engagement surface 22a and the second engagement surface 22b closer. Due to the sliding movement, the unit terminal 12 received in the corresponding first terminal hole 20a and the second terminal hole 20b is thus engaged between the first engagement surface 22a and the second engagement surface 22b. Figure 4a As shown, in an example in which the unit terminals 12 are respectively arranged in respective (exclusive) first terminal holes 20 a and second terminal holes 20 b , the associated first engagement surfaces 22 a and second engagement surfaces 22 b may engage with opposite sides of the corresponding unit terminals 12 .

[0062] Still refer to Figure 4a In some examples, the corresponding first and second engagement surfaces 22a, 22b may be substantially parallel to each other. This makes it possible to maximize the surface area of ​​each engagement surface 22a, 22b in contact with the corresponding unit terminal 12 when the first and second alignment members 18a, 18b are slid together, thereby providing more grip for aligning and holding the unit terminal 12 in place.

[0063] The first alignment member 18a and the second alignment member 18b are preferably connected together and constrained relative to each other to limit the sliding relationship to a substantially linear sliding movement. Therefore, the relative sliding relationship can be limited to a linear sliding motion along the sliding axis S. This simple relationship helps reduce wear and improve the usability of the alignment fixture 10. In addition, in some examples, the first engagement surface 22a and the second engagement surface 22b can be substantially perpendicular to the sliding axis S. This configuration helps to use substantially all of the sliding force applied to the first alignment member 18a and / or the second alignment member 18b as a clamping force to engage with the corresponding terminal 12 between the corresponding first engagement surface 22a and the second engagement surface 22b.

[0064] Now refer to Figure 4b , which shows a schematic close-up view of multiple terminal holes 20a, 20b and associated engagement surfaces 22a, 22b. In some examples, after alignment in the alignment fixture 10, the cell terminals 12 extending into the terminal holes 20a, 20b can be electrically connected to other cell terminals 12 or other components. Therefore, in some examples, the first engagement surface 22a can include an access port 28, which facilitates reaching one side of the corresponding battery cell terminal 12 engaged by the first engagement surface 22a when in use. As previously described, in the examples shown in the aforementioned figures, the first engagement surface 22a can be defined by a plurality of spaced-apart protrusions 24, respectively. It can be seen that in some examples, the access port 28 of each first engagement surface 22a can be defined between two or more protrusions 24 (which define the first engagement surface 22a).

[0065] In particular, in examples where the alignment fixture 10 includes an interconnect bar 30 that defines a second engagement surface 22 b, the access opening 28 may facilitate access to one side of the respective cell terminal 12 for soldering the respective terminal 12 to the interconnect bar 30. In such examples, the parallel engagement surfaces 22 a, 22 b also facilitate ensuring that a flat and parallel interface is provided between the respective terminal 12 and the interconnect bar 30, thereby enabling a high quality electrical connection to be formed between the terminal 12 and the interconnect bar 30.

[0066] Now refer to Figure 5aIn some examples, the battery 16 may include a cell housing 32 for arranging and retaining the cells 14. For example, the cell housing 32 may define a plurality of cell compartments 34, and each cell 14 of the battery 16 may be arranged in a cell compartment 34. Thus, the cells 14 may be restrained and held in place relative to each other. In some examples, the cells 14 may be coupled to the respective cell compartments 34 into which the cells 14 are arranged to secure the cells 14 in place.

[0067] like Figure 5b As shown, in some examples, the unit terminal alignment fixture 10 can be connected to the unit housing 32 to align the terminals 12 of the unit 14 held in the unit housing 32. For example, when the unit 14 is constrained in a suitable position in the unit housing 32, the flexible terminals 12 of the unit 14 can then be manipulated by the unit terminal alignment fixture 10, in particular, by the engagement surfaces 22a, 22b of the first alignment member 18a and the second alignment member 18b, to align the unit terminals 12, as previously described. It can be seen that at least one of the first alignment member 18a or the second alignment member 18b (and in some preferred examples, both alignment members) can slide relative to the unit housing 32 to facilitate aligning the terminals 12 as previously described.

[0068] Still refer to Figure 5b In some examples, the alignment fixture 10 can be provided with a fixing (not shown) for fixing the first alignment component 18a and the second alignment component 18b in an appropriate position relative to each other. The fixing can include one or more bolts located at the fixing location 36, which are configured to clamp the alignment components 18a, 18b together. Advantageously, in examples including the unit housing 32, these fixings can be multifunctional and can additionally attach the alignment fixture 10 to the unit housing 32.

[0069] Where a fixture is included, the fixture can help hold the first alignment feature 18a and the second alignment feature 18b in position relative to each other after the first alignment feature 18a and the second alignment feature 18b are slid to engage the cell terminal 12 between the respective first engagement surfaces 22a and the second engagement surfaces 22b. Thus, in some examples, the fixture can help maintain electrical connection between the cell terminal 12 and other components against which the cell terminal is held. Where the cell terminal 12 is to be welded to another component (e.g., an interconnect bar 30 or another cell terminal 12), this fixture can help hold the cell terminal 12 in the correct position until the welding process is complete.

[0070] It should be understood that the description given with reference to the accompanying drawings is intended to provide multiple non-exclusive examples of the present invention defined by the appended claims. Therefore, it should be understood that in some examples, other examples not shown in the accompanying drawings may constitute part of the present invention.

[0071] For example, although Figures 3 to 5b The cell terminals 12 of the cells 14 in the illustrated battery 16 each protrude from the same side of the cell 14, and the cells 14 are all arranged in the same orientation, but in some other examples, the cells 14 may be constructed and arranged differently. For example, each battery cell 14 may have a positive cell terminal 12a and a negative cell terminal 12b, and the positive cell terminal 12a and the negative cell terminal 12b each protrude from a different side of the corresponding cell 14. Examples including such battery cells 14 may feature an arrangement of battery cells 14 oriented in the same manner, such that all positive terminals 12a protrude from a first side of the battery 16, and all negative terminals 12b protrude from a second side of the battery 16. Alternatively, other examples including such cells 14 may feature multiple cells arranged in different orientations, such that a first side of the battery 16 may include a positive cell terminal 12a and a negative cell terminal 12b, and a second side of the battery 16 may also include a positive cell terminal 12a and a negative cell terminal 12b.

[0072] In each example, it should be understood that the battery cell terminal alignment fixture 10 described herein can be used to align multiple terminals 12 on a given side of a battery 16, and in some examples, the alignment fixture 10 can facilitate the electrical connection of the cells 14 as previously described. For example, as previously described, depending on the desired characteristics of the battery 16, where the interconnection bar 30 is included, the interconnection bar 30 of the fixture 10 can connect the positive cell terminals 12a together, connect the negative cell terminals 12b together, and / or connect the positive cell terminals 12a and the negative cell terminals 12b together.

[0073] Furthermore, in examples where the cells 14 have terminals 12 extending from different sides of the respective cells 14, the battery 16 may include a plurality of cell terminal alignment fixtures 10, each fixture 10 being arranged to align the terminals 12 on a respective side of the battery 16. Thus, some examples of the battery 16 may include: a first alignment fixture 10 arranged on a first side of the battery 16 to align the terminals 12 protruding from respective first sides of the plurality of cells 14; and a second alignment fixture 10 arranged on a second side of the battery 16 to align the terminals 12 protruding from respective second sides of the plurality of cells 14.

[0074] As mentioned above Figure 3As described, in some examples, each unit terminal 12 can be arranged in its own corresponding first terminal hole 20a and second terminal hole 20b, respectively. However, although not shown in the drawings, in some examples, the corresponding first terminal hole 20a and second terminal hole 20b can accommodate multiple unit terminals 12. Therefore, by sliding one or both of the alignment components 18a, 18b to bring the first engagement surface 22a and the second engagement surface 22b together, multiple terminals 12 can be gathered between each pair of corresponding engagement surfaces 22a, 22b, and further sliding can bring the unit terminals 12 into contact with each other. Therefore, configuring the alignment fixture 10 to accommodate multiple unit terminals 12 in each terminal hole 20a, 20b can facilitate direct connection between multiple terminals 12 arranged in the corresponding holes 20a, 20b.

[0075] Although not shown in the figures, some examples of the battery 16 described herein may include a battery management control board. Such a control board may be configured to control the voltage across the cells 14 in the battery 16. In examples that include interconnect strips 30, the control board may thus be electrically connected to each strip 30. For example, Figure 5b As shown, in some examples, the interconnection bars 30 may each include a corresponding connection pin 38, and the control board (not shown) may be electrically connected to the corresponding interconnection bar 30 via such connection pins 38. To facilitate connection, such pins 38 may preferably extend outwardly from the battery 16 so that the control board may be mounted to the battery 16 at a later stage in the assembly process after the cell terminals 12 have been aligned in the fixture 10, and preferably after any electrical connections have been made.

[0076] The battery terminal alignment fixture 10 or battery 16 described herein may form part of an electric water heater system (not shown). For example, the electric water heater system may include a battery 16 for providing electrical energy to an electric water heater, such as a resistance heating element. Thus, the battery 16 may be electrically coupled to the electric water heater.

[0077] It should be understood that in some other examples, the battery cell terminal alignment fixture 10 or battery 16 described herein may also be advantageously implemented in other applications utilizing multiple cells 14 connected together (i.e., utilizing battery 16). For example, the alignment fixture 10 or battery 16 may also be used in the transportation field, such as ships, trains, or vehicles, or in the field of power systems for commercial or residential properties, or backup power storage devices, to name a few non-limiting examples.

[0078] It should be understood that any feature described with respect to the various examples above can be easily combined with any other feature described with reference to different examples without departing from the scope of the invention as defined in the appended claims. In addition, it should be understood that the above description and the accompanying drawings are provided as examples only. Therefore, multiple substitutions of the specific examples provided above are possible without departing from the scope of the invention as defined in the appended claims.

Claims

1. A battery cell terminal alignment fixture (10) for aligning protruding terminals (12) of a plurality of battery cells (14), the fixture comprising: A first alignment member (18a) comprising a plurality of first terminal holes (20a) and a corresponding plurality of associated first engagement surfaces (22a); as well as a second alignment member (18b) comprising a plurality of second terminal apertures (20b) and a corresponding plurality of associated second engagement surfaces (22b); wherein the corresponding first terminal hole (20a) and the second terminal hole (20b) are configured to receive the corresponding battery cell terminal (12) together; and The first alignment component (18a) and the second alignment component (18b) are connected together in a sliding relationship, so that one of the first alignment component or the second alignment component slides relative to the other, thereby bringing the corresponding first bonding surface (22a) and the second bonding surface (22b) closer together, thereby clamping the corresponding battery cell terminal (12) between the first bonding surface and the second bonding surface.

2. The battery cell terminal alignment fixture (10) according to claim 1 further includes a plurality of interconnecting strips (30) mounted in the second alignment member (18b), wherein each second engagement surface (22b) is at least partially defined by a corresponding interconnecting strip.

3. The battery cell terminal alignment fixture (10) according to claim 2, wherein: Each first engagement surface (22a) is defined by a respective protrusion (24) extending into a corresponding second terminal aperture (20b) of the second alignment member (18b).

4. The battery cell terminal alignment fixture (10) according to claim 3, wherein: Each first engagement surface (22a) includes an access opening (28) which facilitates access to a side of a corresponding battery cell terminal (12) with which the first engagement surface engages, in use.

5. The battery cell terminal alignment fixture (10) according to claim 3 or claim 4, wherein Each first engagement surface (22a) is defined by a plurality of spaced-apart protrusions (24).

6. A battery cell terminal alignment fixture (10) according to any preceding claim, wherein: The first alignment feature (18a) defines a row of first terminal holes (20a) and a row of corresponding and associated first engagement surfaces (22a), and wherein the second alignment feature (18b) defines a row of second terminal holes (20b) and a row of corresponding and associated second engagement surfaces (22b).

7. The battery cell terminal alignment fixture (10) according to claim 6, wherein: The first alignment feature (18a) defines a plurality of rows of first terminal holes (20a) and a plurality of rows of corresponding and associated first engagement surfaces (22a), and wherein the second alignment feature (18b) defines a plurality of rows of second terminal holes (20b) and a plurality of rows of corresponding and associated second engagement surfaces (22b).

8. A battery cell terminal alignment fixture (10) according to any preceding claim, wherein: Each pair of corresponding first engaging surfaces (22a) and second engaging surfaces (22b) are parallel to each other.

9. A battery cell terminal alignment fixture (10) according to any preceding claim, wherein: The first alignment member (18a) and the second alignment member (18b) are connected together and constrained relative to each other such that the sliding relationship is constrained to a generally linear sliding movement along a sliding axis (S).

10. The battery cell terminal alignment fixture (10) according to claim 9, wherein: The first engagement surface (22a) and the second engagement surface (22b) are substantially perpendicular to the sliding axis (S).

11. A battery cell terminal alignment fixture (10) according to any preceding claim, wherein: The first alignment feature (18a) and the second alignment feature (18b) are formed of an electrically insulating material.

12. The battery cell terminal alignment fixture (10) according to any preceding claim, further comprising a fixture arranged to fix the first alignment feature (18a) and the second alignment feature (18b) in position relative to each other.

13. A battery (16) comprising a plurality of battery cells (14) and a battery cell terminal alignment fixture (10) as claimed in any preceding claim, each battery cell comprising at least one battery cell terminal (12), and the terminal of each cell being arranged in a first terminal hole (20a), in a corresponding second terminal hole (20b), and between a first mating surface (22a) and a corresponding second mating surface (22b).

14. The battery (16) according to claim 13, wherein: The battery cell terminal alignment fixture (10) includes a plurality of interconnecting strips (30) mounted in the second alignment member (18b), wherein each second engagement surface (22b) is at least partially defined by a corresponding interconnecting strip, and wherein each battery cell terminal (12) disposed in a corresponding second terminal hole (20b) is electrically connected to the interconnecting strip defining the associated second engagement surface.

15. The battery (16) according to claim 14, wherein: Each battery cell (14) includes a positive battery cell terminal (12a) and a negative battery cell terminal (12b), and wherein both the positive battery cell terminal and the negative battery cell terminal protrude from the same side of the respective battery cell.

16. The battery (16) according to claim 14, wherein: Each battery cell (14) includes a positive battery cell terminal (12a) and a negative battery cell terminal (12b), and wherein the positive battery cell terminal and the negative battery cell terminal each protrude from a different side of the corresponding battery cell.

17. The battery (16) according to claim 15 or 16, wherein: Each interconnect bar electrically connects a positive battery cell terminal (12a) of the battery cell (14) to a negative battery cell terminal (12b) of a different battery cell.

18. The battery (16) according to claim 15 or 16, wherein: Each interconnect bar (30) electrically connects a positive battery cell terminal (12a) of a battery cell (14) with a positive battery cell terminal (12a) of a different battery cell, or each interconnect bar electrically connects a negative battery cell terminal (12b) of a battery cell with a negative battery cell terminal (12b) of a different battery cell.

19. The battery (16) according to any one of claims 14 to 18, wherein: Each interconnect bar (30) includes a connection pin (38), and wherein the battery further includes a battery management control board electrically connected to each interconnect bar via a corresponding connection pin.

20. The battery (16) according to any one of claims 13 to 19, wherein: Each battery cell terminal (12) arranged in the first terminal hole (20a) and the second terminal hole (20b) of the battery cell terminal alignment fixture (10) is arranged in its own first terminal hole and corresponding second terminal hole respectively.

21. The battery (16) according to any one of claims 13 to 20, further comprising a cell housing (32) defining a plurality of cell compartments (34), wherein: Each battery cell (14) is arranged in a cell compartment so that the cells are held in position relative to each other.

22. The battery (16) according to claim 21, wherein: The battery cell terminal alignment fixture (10) is attached to the cell housing (32).

23. The battery (16) according to claim 22, wherein: At least one of the first alignment member (18a) or the second alignment member (18b) is slidable relative to the unit housing (32).

24. The battery (16) according to claim 23, wherein: The first alignment member (18a) and the second alignment member (18b) are both slidable relative to the unit housing (32).

25. An electric hot water system, comprising the battery unit terminal aligning fixture (10) according to any one of claims 1 to 12.

26. An electric hot water system comprising a battery (16) according to any one of claims 13 to 24.

27. The electric hot water system according to claim 26, further comprising an electric heater for heating water, wherein: The battery (16) is electrically connected to the electric heater to supply power to the electric heater.

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