Method for smart battery assembly

Abstract

A method for assembling a battery is described. The battery has a plurality of battery cells, a post assembly, a plurality of posts, and a plurality of straps. The method includes: coupling each of the plurality of tapes to a battery cell of the plurality of battery cells; coupling each of the plurality of posts to one of the plurality of bands, wherein each coupled post is electrically coupled to one battery cell corresponding to one band; and performing inter-cell coupling between at least one pair of battery cells of the plurality of battery cells by coupling a pair of terminals of the plurality of terminals.

Description

Technical Field

[0001] The present disclosure relates to batteries and, in particular, to the manufacture and / or assembly of intelligent batteries that facilitate battery performance / fault monitoring. Background Art

[0002] With the development of battery technology, the demand for improved power sources (such as energy storage modules for vehicles) continues to grow. Existing battery systems (such as lead-acid battery systems) typically provide limited access to performance and fault monitoring. More specifically, existing lead-acid battery systems may not provide one or more battery parameters (e.g., that can be used to determine performance and / or predict / monitor faults) of one or more battery cells of the lead-acid battery system. In other words, it is difficult for existing lead-acid battery systems to provide information about important components, such as the health status of individual battery cells. As a result, the health status of battery cells cannot be monitored and / or determined, thus hindering the ability to predict upcoming battery failures or the onset of faults. Summary of the Invention

[0003] Some embodiments advantageously provide a method of manufacturing and / or assembling a battery (e.g., using inter-cell welding and / or pre-filling, using post-based inter-cell connections and / or pre-filling, using inter-cell welding and filling, and / or using electrofusion (EF) welding) to provide an arrangement for monitoring the health status of individual battery cells of the battery. In some embodiments, the method includes coupling one or more posts to one or more battery cells, where the one or more battery cells have been electrically and / or physically connected, for example, using inter-cell welding. In some other embodiments, pre-filling is used to assemble the battery cells. In one embodiment, the posts can be electrically connected to a lead assembly and / or a battery management system (BMS), for example, to determine / measure at least one parameter associated with the battery (e.g., an intelligent battery) and / or battery cells, such as cell voltage, current, temperature, etc. In some embodiments, the battery cells, inter-cell connections, BMS, lead assembly, posts, and / or other components are assembled and / or manufactured in the battery, for example, without having to change one or more specifications of the battery.

[0004] According to one aspect, a method for assembling a battery is described. The battery has a plurality of battery cells, a post assembly, a plurality of posts, and a plurality of straps. The method includes: coupling each of the plurality of straps to one of the plurality of battery cells; coupling each of the plurality of posts to one of the plurality of straps, where each of the coupled posts is electrically coupled to one battery cell corresponding to one strap; and performing inter-cell coupling between at least a pair of the plurality of battery cells by coupling a pair of the plurality of posts.

[0005] In some embodiments, a first cast-on-strapping (COS) process is used to perform coupling each of a plurality of straps to one of a plurality of battery cells.

[0006] In some other embodiments, a second COS process is used to perform coupling each of a plurality of terminals to one of the plurality of straps.

[0007] In some embodiments, the method further includes performing one of the following before coupling each strap to a battery cell and coupling each terminal to a strap: filling the battery cell and pre-filling the battery cell.

[0008] In some other embodiments, performing inter-cell coupling of the battery cells includes welding a pair of terminals.

[0009] In some embodiments, performing inter-cell coupling of the battery cells includes electrically coupling a pair of terminals to one of the plurality of straps.

[0010] In some other embodiments, performing inter-cell coupling of the battery cells includes coupling one of the plurality of straps to a pair of battery cells.

[0011] In some embodiments, the battery at least includes an inter-cell connector, and performing inter-cell coupling of the battery cells includes coupling the inter-cell connector to a pair of terminals.

[0012] In some other embodiments, the battery further includes a cover. The cover includes a pair of openings electrically coupled via the inter-cell connector, and the method further includes inserting a pair of terminals through the pair of openings, and the inserted pair of terminals is electrically coupled via the inter-cell connector.

[0013] In some embodiments, the battery is a lead-acid battery.

[0014] According to another aspect, a method for assembling a battery is described. The battery has a plurality of battery cells, a plurality of terminals, and a plurality of straps. The method includes coupling each of the plurality of straps to one of the plurality of battery cells. A first cast-on-strap (COS) process is used to perform the coupling of each of the plurality of straps to one of the plurality of battery cells. The method further includes coupling each of the plurality of terminals to one of the plurality of straps. Each of the coupled terminals is electrically coupled to one of the battery cells corresponding to one of the straps. A second COS process is used to perform the coupling of each of the plurality of terminals to one of the plurality of straps. The method further includes: performing inter-cell coupling between at least a pair of the plurality of battery cells by coupling a pair of the plurality of terminals.

[0015] In some embodiments, the method further includes: performing one of the following before coupling each strap to a battery cell and coupling each terminal to a strap: filling the battery cells and pre-filling the battery cells.

[0016] In some other embodiments, performing inter-cell coupling includes welding a pair of terminals.

[0017] In some embodiments, performing inter-cell coupling includes electrically coupling a pair of terminals to one of the plurality of straps.

[0018] In some other embodiments, performing inter-cell coupling includes coupling one of the plurality of straps to a pair of battery cells.

[0019] In some embodiments, the battery includes at least an inter-cell connector, and performing inter-cell coupling includes coupling the inter-cell connector to a pair of terminals.

[0020] In some other embodiments, the battery further includes a cover. The cover includes a pair of openings electrically coupled via an inter-cell connector, and the method further includes inserting a pair of terminals through the pair of openings. The inserted pair of terminals is electrically coupled via the inter-cell connector.

[0021] According to one aspect, a method for assembling a battery is described. The battery has a plurality of battery cells, a plurality of terminals, a plurality of straps, and inter-cell connectors. The method includes coupling each of the plurality of straps to one of the plurality of battery cells. A first COS process is used to perform coupling each of the plurality of straps to one of the plurality of battery cells. Additionally, the method includes coupling each of the plurality of terminals to one of the plurality of straps. Each of the coupled terminals is electrically coupled to one of the battery cells corresponding to a strap. A second COS process is used to perform coupling each of the plurality of terminals to one of the plurality of straps. Further, the method includes performing an inter-cell coupling between at least a pair of the plurality of battery cells by coupling a pair of the plurality of terminals. Performing the inter-cell coupling includes at least one of the following: welding a pair of terminals, electrically coupling a pair of terminals to one of the plurality of straps, coupling one of the plurality of straps to a pair of battery cells, and coupling an inter-cell connector to a pair of terminals.

[0022] In some embodiments, the method further includes performing one of the following before coupling each strap to a battery cell and coupling each terminal to a strap: filling the battery cells and pre-filling the battery cells.

[0023] In some other embodiments, the battery further includes a cover. The cover includes a pair of openings electrically coupled via an inter-cell connector. The method further includes inserting a pair of terminals through the pair of openings. The inserted pair of terminals is electrically coupled via the inter-cell connector. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] A more complete understanding of the embodiments described herein, their attendant advantages and features, will be more readily understood by reference to the following detailed description considered in conjunction with the accompanying drawings, in which:

[0025] Figure 1 An example battery and one or more components of the example battery in accordance with the principles of the present disclosure are shown;

[0026] Figure 2 An example battery (e.g., exploded view) and one or more components of the example battery in accordance with the principles of the present disclosure are shown;

[0027] Figure 3 An example terminal assembly in accordance with the principles of the present disclosure is shown;

[0028] Figure 4 One or more steps of an example battery assembly process using inter-cell welding and / or pre-filling in accordance with the principles of the present disclosure are shown;

[0029] Figure 5 Shows a flowchart of another exemplary battery assembly process according to the principles of the present disclosure;

[0030] Figure 6 Shows an exemplary component according to the principles of the present disclosure;

[0031] Figure 7 Shows an exemplary assembly of an electrode, a terminal, and a strap according to the principles of the present disclosure;

[0032] Figure 8 Shows exemplary components of an exemplary battery according to the principles of the present disclosure;

[0033] Figure 9 Shows an exemplary inter-cell connection of an exemplary battery; and

[0034] Figure 10 Shows a flowchart of an exemplary battery assembly process according to the principles of the present disclosure;

[0035] Figure 11 Shows a flowchart of another exemplary battery assembly process according to the principles of the present disclosure;

[0036] Figure 12 Shows an exemplary terminal assembly including a terminal according to the principles of the present disclosure;

[0037] Figure 13 Shows an exemplary filling process according to the principles of the present disclosure;

[0038] Figure 14 Shows an exemplary pre-filling process according to the principles of the present disclosure;

[0039] Figure 15 Shows a flowchart of another exemplary battery assembly process according to the principles of the present disclosure;

[0040] Figure 16 Shows an exemplary battery assembly process according to the principles of the present disclosure;

[0041] Figure 17 Shows a flowchart of another exemplary battery assembly process according to the principles of the present disclosure;

[0042] Figure 18 Shows a flowchart of another exemplary battery assembly process according to the principles of the present disclosure;

[0043] Figure 19 Shows a flowchart of an exemplary battery assembly process according to the principles of the present disclosure; and

[0044] Figure 20 FIG. 1 shows a flow chart of another example battery assembly process in accordance with the principles of the present disclosure. DETAILED DESCRIPTION

[0045] As battery technology develops, there is a need to provide improved power sources and more efficient and cost-effective methods for manufacturing and / or assembling such power sources as compared to conventional systems and methods.

[0046] Accordingly, the embodiments described and illustrated herein provide a method of manufacturing and / or assembling a smart battery (e.g., using inter-cell welding and / or pre-filling and / or filling and / or inter-cell connectors, etc.).

[0047] Figure 1 and Figure 2 FIG. 2 shows an example battery (e.g., a lead acid battery having a smart absorbent glass mat (AGM) battery assembly) and one or more components of the example battery. The battery 10 may include at least one of the following: a housing 12 (which may be made of resin or any other suitable material), one or more cells 14, a post assembly 15 (e.g., a cast-on-strap (COS) post assembly), a strap 16, one or more posts 18 (e.g., terminal posts, small posts), a first cover 20, one or more sleeves 22 (e.g., U1 sleeves, small sleeves), a lead assembly 24 (e.g., a lead frame), a battery management system 26 (e.g., including a board), one or more fasteners 28, a second cover 30, a harness 32, a vehicle connector 34, a third cover 36, and one or more terminal caps 38. The post assembly 15 may include one or more posts 18 and / or one or more straps 16. In some embodiments, the post assembly 15 includes one strap 16 for each post 18 (e.g., coupled together). In some other embodiments, the strap 16 may be coupled to more than one post 18.

[0048] Figure 3 FIG. 3 shows an example post assembly 15 in accordance with the principles of the present disclosure. The post assembly 15 may be formed / manufactured using a COS process, and the process post assembly may include (e.g., welded, formed, etc. in an integral configuration in combination with the post assembly 15) a strap 16 and a post 18, and / or a fixture box 40. In some embodiments, the fixture box 40 is used to manufacture the post assembly 15 and is not part of the manufactured post assembly 15.

[0049] Figure 4Shows one or more steps of an example battery assembly process using inter-cell welding and / or pre-filling in accordance with the principles of the present disclosure. At step S100, a terminal assembly 15 including one or more terminals 18 (e.g., terminals 18a, 18b) and a strap 16 is coupled to one or more battery cells 14 (e.g., battery cells 14a, 14b). The battery cells 14 may be pre-filled (i.e., filled with one or more components, such as one or more plates 100 and / or other components, e.g., before coupling the terminal assembly 15 to the battery cells 14). The plates 100 may include cathode plates, anode plates, positive / negative grids, separators, etc. Pre-filling may include covering and / or sealing the battery cells. A portion of the plate 100 (e.g., plate tab 102) may be exposed (i.e., protrude from the battery cell). The plate tabs 102 of each battery cell 14 may be interconnected, for example, before coupling the terminal assembly 15 to the battery cells 14).

[0050] In this example, the first battery cell 14a is shown as including a plurality of plates 100 and / or a plurality of plate tabs 102. Each plate tab 102 may be coupled to a corresponding plate 100 and provide one or more electrical connections to the corresponding plate 100. Each of the plurality of plates 100 and / or each of the plurality of plate tabs 102 may be interconnected with the corresponding plate 100 and / or plate tab 102, respectively. The interconnection may include physically coupling and / or electrically coupling (e.g., welding). The interconnection may include using plate connectors to couple the plates 100 and / or plate tabs 102. The interconnected plates 100 and / or plate tabs 102 may form a single unit, such as a plate group and / or a plate tab group. Further, a second battery cell 14b is also shown. As part of the pre-filling step, the second battery cell 14 may be covered. Although the first battery cell 14a is shown as uncovered (i.e., for ease of understanding), the first battery cell 14a is not limited thereto and may be covered as is the second battery cell 14b.

[0051] Coupling the terminal assembly 15 to the first battery cell 14a and the second battery cell 14b (and / or more battery cells) may include coupling the terminal assembly 15 (e.g., directly, indirectly, physically, electrically) to one or more plates 100 and / or one or more plate tabs 102. Further, coupling the terminal assembly 15 to the first battery cell 14a and the second battery cell 14b may include coupling the terminals 18 (e.g., directly, indirectly, physically, electrically) to the corresponding battery cell 14 and / or the corresponding plurality of plates 100 and / or the corresponding plurality of plate tabs 102. For example, the terminal 18a may be coupled to: the battery cell 14a and / or the plates 100 of the battery cell 14a and / or the plate tabs 102 of the battery cell 14a. Similarly, the terminal 18b may be coupled to: the battery cell 14b and / or the plates 100 of the battery cell 14b and / or the plate tabs 102 of the battery cell 14b. In other words, by coupling the terminal assembly 15 and / or the terminals 18 to the battery cell 14, an inter-cell coupling (e.g., connection) may be formed, for example, between plates 100 having the same (or different) polarities in the first battery cell 14a and the second battery cell 14b. The coupling (and / or inter-cell coupling) may include welding and / or any other coupling process / step.

[0052] In some embodiments, pre-filling refers to inserting (e.g., partially inserting) a plurality of plates 100 (and / or plate tabs 102) into the housing 12 (such as a container (e.g., plastic case)) before connecting the lugs of the plates 100 through a cast-on-strap process (COS). In some other embodiments, on an AGM battery, a compression frame may be used to size the plurality of plates 100 to fit into the container. In one or more embodiments, partial insertion may mean inserting such that a portion is not inserted (i.e., another portion is inserted), such as 1 / 4 of the plurality of plates 100 extending outside the housing 12.

[0053] In some other embodiments, a jig box 40 may be used, and the jig box may refer to the tool part of a COS machine / process that holds the housing 12 (such as a container (e.g., plastic case)) having a plurality of plates pre-filled through the process steps of the cast-on-strap process.

[0054] In one or more embodiments, the jig box 40 (e.g., COS jig box) may be arranged to determine the position of a product / component (e.g., a plurality of plates pre-filled in a container). The position may be an accurate positioning / location determined during the process steps of the cast-on-strap process. The jig box 40 may further be used as a carrier to transport the product / component through the process steps performed by the COS machine.

[0055] Figure 5Shows another example assembly process (i.e., method) of battery 10 in accordance with the principles of the present disclosure. The method includes one or more of the following: pre-filling one or more battery cells (block S102); performing (block S104) a first cast-on-strap (COS) on one or more battery components such as terminal assembly 15 and one or more battery cells 14; and performing (block S106) a second cast-on-strap (COS) on one or more other battery components such as terminals 18 (e.g., micro-terminals) and / or terminal assembly 15, with at least one of the first COS and the second COS forming an inter-cell connection between the pre-filled one or more battery cells.

[0056] In some embodiments, either the first COS or the second COS includes casting a strap onto the pre-filled one or more battery cells 14 (e.g., a book).

[0057] In some other embodiments, the method further includes performing encapsulation and / or stacking of the battery cells 14.

[0058] In an embodiment, pre-filling is performed using a pre-filling tool. The pre-filling tool can be arranged / configured to arrange and fix one or more books (e.g., multiple plates, battery cells) in a frame to position the one or more books above the housing 12. Another tool including a pusher can be arranged to press the book into the housing 12. In the pre-filling process, the book can be moved / inserted into the container (e.g., not completely moved / inserted into the container). That is, the insertion can be partial, e.g., to ensure that the plates extend outside the housing 12 such that the cast-on-strap process can be performed on such an arrangement in a COS machine.

[0059] In another embodiment, for a container (i.e., housing 12) having a book (i.e., battery cell 14), the first COS is performed using a jig box 40.

[0060] In some embodiments, the second COS is performed using a mold (e.g., having a predetermined spacing, such as a small spacing).

[0061] In some other embodiments, the battery cells 14 (i.e., pre-filled battery cells) are inserted (i.e., loaded) into the housing 12.

[0062] In an embodiment, the height of each terminal 18 is tested. This test can be performed using a probe (such as a mechanical probe), e.g., to detect the height (of the terminal at the level of the housing 12). The height can also be measured using a camera or a 3D scanner (e.g., non-contact).

[0063] In another embodiment, the battery 10 further includes a terminal assembly 15 and one or more terminals 18. One or more battery components associated with the first COS include the terminal assembly 15 and one or more battery cells 14, while one or more other battery components associated with the second COS include the terminals 18 (e.g., small terminals) and / or the terminal assembly 15. The first COS and the second COS electrically connect at least one of the terminal assembly 15 and the one or more terminals 18 to the one or more battery cells 14.

[0064] In another embodiment, the inter-cell welding is performed at least by welding the terminal assembly 15 to the one or more battery cells 14.

[0065] In some embodiments, the inter-cell welding is performed using welding pliers.

[0066] In some other embodiments, the method includes aligning each terminal 18 with at least one other terminal 18.

[0067] In an embodiment, each terminal 18 is aligned with at least one other terminal 18 using an alignment tool. The alignment tool may have a gauge plate having sleeves that align the terminals by moving the alignment gauge over the assembly. Further, the alignment tool may have a gripper (e.g., an automatic gripper or multiple grippers) that aligns the terminals to a predetermined position.

[0068] In some embodiments, the battery 10 further includes a first cover 20 coupled to the housing 12.

[0069] In some other embodiments, coupling the first cover 20 to the housing 12 includes performing at least one of the following:

[0070] Sealing the first cover 20 to the housing 12; and

[0071] Welding (e.g., tungsten inert gas (TIG) welding, flame welding) the first cover 20 to the housing 12.

[0072] In one or more embodiments, the method further includes connecting (e.g., physically, electrically) a portion (e.g., a strip) of the battery cell 14 to a sleeve of the first cover 20. The connection may include using automatic post burn (APB).

[0073] In an embodiment, the battery 10 further includes a lead assembly 24 and a battery management system 26, the battery management system being configured to determine and / or measure at least one battery cell parameter. The method further includes: electrically coupling one or more terminals 18 to the lead assembly 24; and electrically coupling the lead assembly 24 to the battery management system 26.

[0074] In another embodiment, the method further includes at least one of the following: testing terminal height; testing battery height; and performing a leak test on the battery 10.

[0075] Figure 6 An exemplary element 110 of the battery 10 in accordance with the principles of the present disclosure is shown. More specifically, a battery cell 14, a terminal assembly 15 (including straps 16 and terminals 18, i.e., a cast-on-strap (COS) terminal assembly), and the element 110 are shown. The strap 16 having the terminals 18 can be cast onto the battery cell 14 to form the element 110, which can include a plate 100. The casting can occur after the book-shaped body (battery cell 14) is pre-filled (i.e., partially inserted) into the battery housing (or container). The element 110 can include or be a book-shaped body or a stack. However, the element 110 is not limited to a book-shaped body or a stack and can include or take other structural forms, such as a wound coil.

[0076] Figure 7 is an exemplary assembly of a plate 100, a strap 16, and a terminal 18 in accordance with the principles of the present disclosure. Each element 110 has a strap 16, the straps including terminals 18 for each polarity. More specifically, the terminal assembly 15a includes a strap 16a coupled to a terminal 18a. The terminal assembly 15a is coupled to one or more plates 100 and can have a first polarity (e.g., positive). Similarly, the terminal assembly 15b includes a strap 16b coupled to a terminal 18b. The terminal assembly 15b is coupled to one or more plates 100 and can have a second polarity (e.g., negative).

[0077] Figure 8Shows exemplary components of an exemplary battery 10. The battery 10 can include a strap 16, terminals 18, a cover 200, and a housing 208. The housing 208 (e.g., container, enclosure) can include one or more compartments 210 (e.g., six compartments), a set of electrode plates 100 (e.g., a set of electrodes corresponding to a first polarity and another set of electrodes corresponding to a second polarity), and one or more terminal assemblies 15 (i.e., the strap 16 and the terminals 18). Each compartment 210 can be arranged to receive one or more electrode plates 100 and two (or any other number) of the terminal assemblies 15 (i.e., the strap 16 and the terminals 18). The strap 16 (e.g., lead connector) and / or the terminals 18 can be arranged to receive lugs and couple to the lugs. The cover 200 can include one or more compartments 206 (e.g., six compartments), where each compartment 206 corresponds to a compartment 210. Further, the cover 200 can include one or more openings 202 (e.g., where each opening can include a bushing 22), and at least one opening 202 is arranged to receive a corresponding terminal 18 (e.g., terminal post, cell terminal, etc.) and couple it to the cover 200 via the bushing 22. Additionally, the cover 200 can include one or more inter-cell connectors 204 (i.e., conductor plates, bus bars, inter-cell connectors, etc.), and the one or more inter-cell connectors are arranged to electrically couple the terminals 18 of at least two adjacent compartments 206. The inter-cell connectors 204 can be integrated with the cover 200. Thus, the cover 200 can be placed over the plurality of terminals 18 and the strap 16, and the terminals 18 are inserted through the corresponding openings 202 (and bushings 22). In a non-limiting example, one terminal 18 is electrically coupled to the cover 200, and the other terminal 18 is coupled to the cover (e.g., but not electrically connected to the cover). The remaining terminals 18 can be connected in pairs via the inter-cell connectors 204 of the cover 200 to form inter-cell connections. Step S210 can include inserting the electrode plates 100, the strap 16, and the terminals 18 into the corresponding compartments 210. Step S210 can also include coupling the cover 200 to the housing 208, where the terminals 18 project through the openings 202 and extend away from the cover 200, thereby establishing inter-cell electrical connections via the inter-cell connectors 204. In some embodiments, the cover 200 can be the same as or similar to the first cover 20, and the housing 208 can be the same as or similar to the housing 12.

[0078] Figure 9Shows an example inter-cell connection in accordance with the principles of the present disclosure. More specifically, a plurality of battery cells 14 (i.e., battery cells 14a, 14b, 14c, 14c) are shown. Each battery cell 14 may be contained within a container or stack body and may correspond to partition 206 and / or partition 210. Each battery cell 14 (which may include element 110) and may include at least one cell connector 220 (e.g., including a terminal and / or a bushing), and the at least one cell connector may be arranged to electrically and / or physically connect to any component of the battery cell 14. For example, the cell connector 220 may be arranged to physically / electrically connect (e.g., couple to) one or more plates 100. In some embodiments, the cell connector 220 may include or be connected to a terminal 18 coupled to a bushing 22. In some embodiments, the cell connector 220 may be a terminal connector or a cell connector. Further, the cell connector 220 may be arranged to receive and / or electrically and / or physically connect (e.g., couple to) one or more inter-cell connectors 204. The cell connector 52 may also be arranged to receive and / or physically / or electrically connect (e.g., couple) to a fastener 222. The inter-cell connector 204 may include one or more openings arranged to receive one or more fasteners 222 and arranged to interconnect (e.g., physically and / or electrically connect) one or more battery cells 14. For example, battery cells 14a, 14b may be interconnected via an inter-cell connector 204, which may be received by two cell connectors 220, where each cell connector 220 corresponds to a battery cell 14. The inter-cell connector 204 may be fastened using a fastener 222 and a corresponding cell connector 220 (e.g., below the inter-cell connector 204).

[0079] That is, by using the cell connector 220 and / or the inter-cell connector 204 and / or the fastener 222, two or more battery cells 14 (e.g., battery cells 14a, 14b) can be interconnected, which can form and / or maintain an electrical connection between the battery cells 14. Any one of the cell connector 220, the inter-cell connector 204, and the fastener 222 may be arranged to releasably couple to any component of the battery 10, such as a battery cell 14 (and / or any of its components), a cell connector 220, an inter-cell connector 204, a fastener 222, a terminal assembly 15, a terminal 18 (e.g., a small terminal), one or more bushings 22, a lead assembly 24, a battery management system 26, etc.

[0080] Figure 10FIG. 0 is a flowchart of an example assembly process (i.e., method) of battery 10 in accordance with the principles of the present disclosure. Battery 10 includes an inter-cell busbar 44, at least one terminal 18, and a plurality of battery cells 50. The method includes one or more of the following: pre-filling at least one of the plurality of battery cells 14 (block S102); and performing (block S104) an inter-cell connection of at least a first battery cell 14a and a second battery cell 14b of the plurality of battery cells 14. The performed inter-cell connection includes at least one of the following: coupling the first battery cell 14a to the second battery cell 14b via an inter-cell busbar (i.e., inter-cell connector 204); and coupling at least one terminal 18 to at least one of the inter-cell busbar (i.e., inter-cell connector 204), the first battery cell 14a, and the second battery cell 14b.

[0081] In some embodiments, battery 10 further includes a first cell connector 220a and a second cell connector 220b, and each of the first battery cell 14a and the second battery cell 14b includes a plurality of plates 100 (e.g., electrodes), and the method further includes coupling the first cell connector 220a to the plurality of plates 100 of the first battery cell 14a; and coupling the second cell connector 220b to the plurality of plates 100 of the second battery cell 14b.

[0082] In some other embodiments, the method further includes coupling the first cell connector 220a to the inter-cell connector 204; and coupling the second cell connector 220b to the inter-cell connector 204.

[0083] In an embodiment, battery 10 further includes a first fastener 222a and a second fastener 222b. The method further includes coupling the first fastener 22a to the inter-cell connector 204 and the first cell connector 220a at least by fastening the first fastener 222a to the first cell connector 220a; and coupling the second fastener 222b to the inter-cell connector 204 and the second cell connector 220b at least by fastening the second fastener 222b to the second cell connector 220b. The fastening of the first fastener 222a and the second fastener 222b secures the inter-cell connector 204 to each of the first battery cell 14a and the second battery cell 14b and forms a connection between the first battery cell 14a and the second battery cell 14b.

[0084] In another embodiment, coupling at least one terminal 18 to at least one of the inter-cell connectors 204, the first cell 14a, and the second cell 14b further includes coupling at least one terminal 18 to at least one of the first cell connector 220a and the second cell connector 220b.

[0085] In some embodiments, the battery 10 further includes a cover 200 that includes at least one sleeve 22 coupled to the inter-cell connector 204, wherein at least one terminal 18 is coupled to at least one sleeve 22 to perform at least an inter-cell connection.

[0086] Figure 11 is a flowchart of another example assembly process (i.e., method) of the battery 10 in accordance with the principles of the present disclosure. At step S400, a stack body (i.e., cell 14) is pre-filled into the housing 208 (e.g., inserted as shown Figure 8 ). At step S402, the method includes casting a strip 16 having terminals 18 onto an element 110. At step S404, the method includes inserting (e.g., fully inserting, filling into, etc.) the element 110 into the housing 208. At step S406, the terminals 18 are aligned to ensure the positions of the sleeves in the cover 200 for assembly. At step S408, the method includes heat-sealing the cover 200 (e.g., the main cover) to the housing 208, and at step S410, the method includes performing automatic terminal welding on the terminals (e.g., terminals 18 and / or sleeves 42).

[0087] Figure 12 An example terminal assembly 15 including a strip 16 and terminals 18 in accordance with the principles of the present disclosure is shown. More specifically, the terminal assembly 15 includes at least one strip 16 and one terminal 18. A process can be performed to manufacture the terminal assembly 15. The process can be Figure 5 the process shown (or any other process) and includes casting the strip 16 having terminals 18. The process can be a cast-on-strap (COS) process for grouping and connecting elements of the battery 10. The terminal assembly 15 can be arranged to be received by (and / or connected to) the cells 14. That is, when the process is performed, the terminal assembly 15 includes one or more terminals 18 that are formed or assembled to be available for connecting each terminal 18 to one or more corresponding cells 14, for example, as shown Figure 2 . Further, the terminals 18 are arranged to be connectable to the lead assembly 24 and / or the BMS 26, such that the BMS 26 is electrically connected to the cells 14 via the terminals 18 of the terminal assembly 15 and is configured to determine at least one parameter of the cells 14.

[0088] Figure 13 An example filling process is shown, for example, casting a tape onto a booklet without pre-filling. At step S500, a set of battery cells 14 (e.g., a set of n booklets) are arranged in a gripper of a machine, for example. At step S502, a terminal assembly 15 is cast (e.g., coupling the booklet to the cast tape) and / or the terminal assembly is arranged in the gripper machine. At step S504, a set of n components 110 (e.g., having a booklet with a cast tape or battery cell 14) are inserted into a housing 12, for example, where each battery cell 14 (e.g., booklet) is entirely within a compartment of the housing 12. In some embodiments, each component 110 is entirely within a compartment of the housing 12. That is, filling may refer to fully inserting the battery cell (booklet) into the housing 12.

[0089] Figure 14 An example pre-filling process is shown, for example, casting a tape onto a pre-filled booklet. At step S600, a set of battery cells 14 (e.g., a set of n booklets) are arranged in a gripper of a machine, and pre-filling is performed (e.g., partially inserting into the housing 12). At step S602, a terminal assembly 15 is cast (e.g., coupling the booklet to the cast tape 16), where the component 110 is partially inserted into the housing 12 and / or arranged in the gripper machine. At step S604, a set of n components 110 (e.g., having a booklet with a cast tape) can be fully inserted into the housing 12, for example, where each battery cell 14 (e.g., booklet) is entirely within a compartment of the housing 12. In some embodiments, each component 110 is entirely within a compartment of the housing 12. That is, steps S600 and S602 may refer to pre-filling, and step S604 may refer to fully inserting the booklet into the housing 12, i.e., filling.

[0090] Figure 15FIG. 0 is a flow chart of another example assembly process (i.e., method) of battery 10 in accordance with the principles of the present disclosure. Battery 10 includes first battery cell 14a, second battery cell 14a, first strap 16a and first terminal 18a connected to first strap 16a, and second strap 16b and second terminal 18b connected to second strap 16b. The method includes one or more of the following: casting (block S700) first strap 16a with connected first terminal 18a onto first battery cell 14a to couple first strap 16a to first battery cell 14a; casting (block S702) second strap 16b with connected second terminal 18b onto second battery cell 14b to couple second strap 16b to second battery cell 14b; and performing (block S704) inter-cell welding on first battery cell 14a and second battery cell 14b. The performed inter-cell welding electrically connects one or both of first strap 16a and first terminal 18a to one or both of second strap 16a and second terminal 18b.

[0091] In some embodiments, casting of one or more straps is performed using an overflow mold having a predetermined spacing.

[0092] In some other embodiments, battery 10 further includes housing 12, and casting of one or more straps 16 is performed using fixture box 40 for housing 12.

[0093] In an embodiment, the method further includes filling a plurality of battery cells 14.

[0094] In some embodiments, one or more of the following steps are performed: encapsulating battery components (such as battery cells 14); stacking battery components (such as battery cells 14); loading (i.e., inserting) battery cells 14 and / or terminal assemblies 15 into housing 12; testing the height of terminals 18; aligning the terminals; sealing first cover 20, second cover 30, third cover 36, and / or cap 38 to another battery component; testing terminal height and / or battery height; and performing a leak test.

[0095] In a non - limiting example, the strap 16 and the terminal 18 are cast in one step. A set of plates 100 (e.g., electrodes with lugs) are connected to each other through a strap - casting process (e.g., by casting of the terminal assembly 15). Then, a battery cell 14 (e.g., a plate group, a stack) including the cast strap 16 to the corresponding terminal 18 (cast in one step) is inserted (filled) into a housing 12 (e.g., a container). Inter - cell welding is performed, where two or more battery cells 14 are interconnected via at least a portion of the terminal assembly 15. A first cover 20 is sealed to the housing 12, where at least a portion of the terminal 18 protrudes outside the first cover 20. A lead assembly 24 is connected to each protruding terminal 18 and to the BMS 26. That is, the BMS 26 is electrically connected to the battery cell 14 via the terminal assembly 15 to perform at least one action associated with the parameters of the battery cell 14, such as measuring the voltage of each battery cell 14.

[0096] Figure 16 An example battery assembly process in accordance with the principles of the present disclosure is shown. At step S800, the strap 16 is placed on two battery cells 14a, 14b. At step S802, inter - cell welding is performed, i.e., the strap 16 is welded to the two battery cells 14a, 14b. At step S804, the terminal 18 is coupled (e.g., welded) to the strap 16. That is, the example process allows the strap 16 to be welded to the battery cell 14 before the terminal 18 is coupled to the strap 16.

[0097] Figure 17 Another example assembly process (i.e., method) of the battery 10 in accordance with the principles of the present disclosure is shown. The battery 10 includes a plurality of battery cells 14 and a terminal assembly 15. The terminal assembly 15 includes one or more straps 16 and one or more terminals 18. The method includes one or more of the following: casting (block S900) one or more straps 16 without one or more terminals 18; performing (block S902) inter - cell welding of two or more of the plurality of battery cells 14, where the performed inter - cell welding electrically connects at least one of the one or more straps 16 without terminals 18 to at least two of the plurality of battery cells 14; and welding and / or casting (block S904) one or more terminals 18 to the cast one or more straps 16 to form the terminal assembly 15.

[0098] In some embodiments, an overflow die is used to perform the casting of one or more straps 16.

[0099] In some other embodiments, the casting of one or more terminals includes lead - casting of one or more terminals 18.

[0100] In an embodiment, rotational friction welding is used to perform the welding of one or more terminals 18.

[0101] In another embodiment, the welding of one or more terminals 18 includes welding one or more terminals 18 using a resistance welding process.

[0102] In one or more embodiments, the welding may include inter-cell (IC) welding, electrofusion (EF) welding, through partition (TTP) welding, resistance welding, etc. In an embodiment, IC welding may refer to or include EF welding and / or TTP welding.

[0103] In some embodiments, one or more of the following steps are performed: encapsulating battery components (such as battery cells 14); stacking battery components (such as battery cells 14); loading battery cells 14 and / or terminal assemblies 15 into the housing 12; testing the height of the terminals 18; aligning the terminals; sealing the first cover 20, the second cover 30, the third cover 36, and / or the cap 38 to another battery component; testing the terminal height and / or the battery height; and performing a leak test.

[0104] In a non-limiting example, the terminal assembly 15 includes five terminals 18 (e.g., small terminals). The terminal assembly 15 is formed by casting one or more strips without one or more terminals 18 and welding or casting one or more terminals 18 to the cast one or more strips 16. Subsequently, the terminal assembly 15 is placed on the battery cells 14, which may have been previously placed in the housing 12 or are prepared to be placed in the housing 12 subsequently. Inter-cell welding is performed, wherein each of the five terminals 18 is coupled to (e.g., welded to) and / or electrically connected to the battery cell 14, and / or two or more battery cells 14 are interconnected via at least a portion of the terminal assembly 15. The first cover 20 is sealed to the housing 12, wherein at least a portion of the terminal 18 protrudes outside the first cover 20. The lead assembly 24 is connected to each protruding terminal 18 and to the BMS 26. That is, the BMS 26 is electrically connected to the battery cell 14 via the terminal assembly 15 to perform at least one action associated with the parameters of the battery cell 14, such as measuring the voltage of each battery cell 14.

[0105] Figure 18Another example battery assembly method is shown. The battery has a plurality of battery cells 14, a plurality of straps 16, and a plurality of terminals 18. The method includes: coupling each of the plurality of straps 16 (block S1000) to one of the plurality of battery cells 14; coupling each of the plurality of terminals 18 (block S1002) to one of the plurality of straps 16, wherein each coupled terminal 18 is electrically coupled to one battery cell 14 corresponding to one strap 16; and performing (block S1004) an inter-cell coupling between at least a pair of the plurality of battery cells 14 by coupling a pair of the plurality of terminals 18.

[0106] In some embodiments, a first COS process is used to perform coupling each of the plurality of straps 16 to one of the plurality of battery cells 14.

[0107] In some other embodiments, a second COS process is used to perform coupling each of the plurality of terminals to one of the plurality of straps.

[0108] In some embodiments, the method further includes: performing one of the following before coupling each strap 16 to one battery cell 14 and coupling each terminal 18 to one strap 16: filling the battery cells 14 and pre-filling the battery cells 14.

[0109] In some other embodiments, performing the inter-cell coupling includes welding a pair of terminals 18.

[0110] In some embodiments, performing the inter-cell coupling includes electrically coupling a pair of terminals 18 to one of the plurality of straps 16.

[0111] In some other embodiments, performing the inter-cell coupling includes coupling one of the plurality of straps 16 to a pair of battery cells 14.

[0112] In some embodiments, the battery 10 includes at least an inter-cell connector 204, and performing the inter-cell coupling includes coupling the inter-cell connector 204 to a pair of terminals 18.

[0113] In some other embodiments, the battery further includes covers 20, 200. The covers 20, 200 include a pair of openings 202 electrically coupled via the inter-cell connector 204. The method further includes inserting a pair of terminals 18 through the pair of openings 202, wherein the inserted pair of terminals 118 are electrically coupled via the inter-cell connector 204.

[0114] In some embodiments, the battery 10 is a lead-acid battery.

[0115] Figure 19 illustrates an exemplary battery assembly method. The battery has a plurality of battery cells 14, a plurality of straps 16, and a plurality of terminals 18. The method includes coupling (block S1100) each of the plurality of straps 16 to one of the plurality of battery cells 14. A first COS process is used to perform coupling each of the plurality of straps 16 to one of the plurality of battery cells 14. The method further includes coupling (block S1102) each of the plurality of terminals 18 to one of the plurality of straps 16, wherein each coupled terminal 18 is electrically coupled to one battery cell 14 corresponding to one strap 16. A second COS process is used to perform coupling each of the plurality of terminals to one of the plurality of straps. Further, the method includes performing (block S1104) an inter-cell coupling between at least a pair of the plurality of battery cells 14 by coupling a pair of the plurality of terminals 18.

[0116] In some embodiments, the method further includes performing one of the following before coupling each strap 16 to one battery cell 14 and coupling each terminal 18 to one strap 16: filling the battery cells 14 and pre-filling the battery cells 14.

[0117] In some other embodiments, performing the inter-cell coupling includes welding a pair of terminals 18.

[0118] In some embodiments, performing the inter-cell coupling includes electrically coupling a pair of terminals 18 to one of the plurality of straps 16.

[0119] In some other embodiments, performing the inter-cell coupling includes coupling one of the plurality of straps 16 to a pair of battery cells 14.

[0120] In some embodiments, the battery 10 includes at least an inter-cell connector 204, and performing the inter-cell coupling includes coupling the inter-cell connector 204 to a pair of terminals 18.

[0121] In some other embodiments, the battery further includes covers 20, 200. The covers 20, 200 include a pair of openings 202 that are electrically coupled via the inter-cell connector 204. The method further includes inserting a pair of terminals 18 through the pair of openings 202, wherein the inserted pair of terminals 118 are electrically coupled via the inter-cell connector 204.

[0122] Figure 20An example battery assembly method is shown. The battery has a plurality of battery cells 14, a plurality of straps 16, and a plurality of terminals 18. The method includes coupling (block S1100) each of the plurality of straps 16 to one of the plurality of battery cells 14. The coupling of each of the plurality of straps 16 to one of the plurality of battery cells 14 is performed using a first COS process. The method further includes coupling (block S1102) each of the plurality of terminals 18 to one of the plurality of straps 16, wherein each coupled terminal 18 is electrically coupled to one battery cell 14 corresponding to one strap 16. The coupling of each of the plurality of terminals to one of the plurality of straps is performed using a second COS process. Further, the method includes performing (block S1204) an inter-cell coupling between at least a pair of the plurality of battery cells 14 by coupling a pair of the plurality of terminals 18. Performing the inter-cell coupling includes at least one of the following: welding a pair of terminals 18, electrically coupling a pair of terminals 18 to one of the plurality of straps 16, coupling one of the plurality of straps 16 to a pair of battery cells 14, and coupling an inter-cell connector 204 to a pair of terminals 18.

[0123] In some embodiments, the method further includes performing one of the following before coupling each strap 16 to one battery cell 14 and coupling each terminal 18 to one strap 16: filling the battery cells 14 and pre-filling the battery cells 14.

[0124] In some other embodiments, the battery 10 further includes covers 20, 200. The covers 20, 200 include a pair of openings 202 that are electrically coupled via an inter-cell connector 204. The method further includes inserting a pair of terminals 18 through the pair of openings 202, and the inserted pair of terminals 18 are electrically coupled via the inter-cell connector 204.

[0125] One or more embodiments of the present disclosure advantageously provide an arrangement for providing individual terminals (e.g., terminal 18) to respective cells 14 within a battery 10 to facilitate the ability to monitor each individual cell 14 of the battery 10, such as by coupling a lead assembly 24 to the terminal 18 to allow electrical connectivity from each cell 14 (via the corresponding terminal 18) to a BMS 26. One or more embodiments are beneficial at least in terms of providing inter-cell connections. The inter-cell connections may be established by an inter-cell connector 204 (external to the cells 14) that connects sleeves 42 and / or terminals 18 from two or more cells. In some other embodiments, the inter-cell connections may be integrated with the covers 20, 200.

[0126] The following are a list of non-limiting example embodiments.

[0127] A1. A method for assembling a battery having one or more cells, the method comprising at least one of the following:

[0128] Pre-filling the one or more cells;

[0129] Performing a first cast-on strap (COS) on one or more battery components; and

[0130] Performing a second cast-on strap (COS) on one or more other battery components, with at least one of the first COS and the second COS forming at least an inter-cell connection between the pre-filled one or more cells.

[0131] A2. The method according to embodiment A1, wherein either the first COS or the second COS includes casting a strap onto the pre-filled one or more cells.

[0132] A3. The method according to any one of embodiments A1 and A2, the method further comprising: performing encapsulation and / or stacking of the cells to pre-fill the one or more cells.

[0133] A4. The method according to any one of embodiments A1 to A3, wherein the pre-filling is performed using a pre-filling tool.

[0134] A5. The method according to any one of embodiments A1 to A4, wherein the first COS is performed using a jig box for a container having a book-like body.

[0135] A6. The method according to any one of embodiments A1 to A5, wherein the second COS is performed using a mold.

[0136] A7. The method according to any one of Embodiments A1 to A6, wherein the battery further includes a terminal assembly and one or more terminals, the one or more battery components associated with the first COS include the terminal assembly and the one or more battery cells, and the one or more other battery components associated with the second COS include the one or more terminals and / or the terminal assembly, and the first COS and the second COS electrically connect at least one of the terminal assembly and the one or more terminals to the one or more battery cells.

[0137] A8. The method according to Embodiment A7, wherein the method further includes: performing inter-cell welding of the battery cells at least by welding the terminal assembly to the one or more battery cells.

[0138] A9. The method according to Embodiment A8, wherein the inter-cell welding of the battery cells is performed using welding pliers.

[0139] A10. The method according to any one of Embodiments A7 to A9, wherein the battery further includes a lead assembly and a battery management system, the battery management system is configured to determine and / or measure at least one battery cell parameter, and the method further includes:

[0140] electrically coupling the one or more terminals to the lead assembly; and

[0141] and electrically coupling the lead assembly to the battery management system.

[0142] A11. The method according to any one of Embodiments A1 to A10, wherein the battery further includes a first cover and a housing, and the method includes coupling the first cover to the housing, and the coupling includes performing one of tungsten inert gas (TIG) welding and flame welding to couple the first cover to the housing.

[0143] B1. A method for assembling a battery, the battery including an inter-cell busbar, at least one terminal, and a plurality of battery cells, the method including at least one of the following:

[0144] pre-filling at least one of the plurality of battery cells; and

[0145] performing an inter-cell connection of at least a first battery cell and a second battery cell among the plurality of battery cells, the performed inter-cell connection including at least one of the following:

[0146] Couple the first battery cell to the second battery cell via the inter-cell bus bar; and couple the at least one terminal to at least one of the inter-cell bus bar, the first battery cell, and the second battery cell.

[0147] B2. The method according to embodiment B1, wherein the battery further includes a first battery cell connector and a second battery cell connector, and each of the first battery cell and the second battery cell includes a plurality of electrodes, and the method further includes:

[0148] Couple the first battery cell connector to the plurality of electrodes of the first battery cell; and

[0149] Couple the second battery cell connector to the plurality of electrodes of the second battery cell.

[0150] B3. The method according to embodiment B2, wherein the method further includes:

[0151] Couple the first battery cell connector to the inter-cell bus bar; and

[0152] Couple the second battery cell connector to the inter-cell bus bar.

[0153] B4. The method according to any one of embodiments B2 and B3, wherein the battery further includes a first bus bar fastener and a second bus bar fastener, and the method further includes:

[0154] Couple the first bus bar fastener to the inter-cell bus bar and the first battery cell connector by at least fastening the first bus bar fastener to the first battery cell connector; and

[0155] Couple the second bus bar fastener to the inter-cell bus bar and the second battery cell connector by at least fastening the second bus bar fastener to the second battery cell connector, the fastening of the first bus bar fastener and the second bus bar fastener fixes the inter-cell bus bar to each of the first battery cell and the second battery cell and forms a connection between the first battery cell and the second battery cell.

[0156] B5. The method according to any one of embodiments B2 to B4, wherein coupling the at least one terminal to at least one of the inter-cell bus bar, the first battery cell, and the second battery cell further includes:

[0157] Couple the at least one terminal to at least one of the first battery cell connector and the second battery cell connector.

[0158] B6. The method according to any one of embodiments B1 to B5, wherein the battery further comprises a cover, the cover comprising at least one sleeve electrically coupled to the inter-cell busbar, and the method further comprises:

[0159] Coupling the at least one terminal to the at least one sleeve to at least effect the inter-cell connection.

[0160] B7. The method according to any one of embodiments B1 to B6, wherein the battery is a lead-acid battery and the at least one terminal is a small terminal.

[0161] C1. A method for assembling a battery, the battery comprising a first battery cell, a second battery cell, a first strap and a first terminal connected to the first strap, and a second strap and a second terminal connected to the second strap, the method comprising one or more of the following:

[0162] Casting the first strap with the connected first terminal into the first battery cell to couple the first strap to the first battery cell;

[0163] Casting the second strap with the connected second terminal into the second battery cell to couple the second strap to the second battery cell; and

[0164] Performing inter-cell welding on the first battery cell and the second battery cell, the performed inter-cell welding electrically connecting one or both of the first strap and the first terminal to one or both of the second strap and the second terminal.

[0165] C2. The method according to embodiment C1, wherein casting of the first strap and the second strap is performed using an overflow mold having a predetermined spacing.

[0166] C3. The method according to any one of embodiments C1 and C2, wherein the battery further comprises a housing, and casting of the first strap and the second strap is performed using a jig box for the housing.

[0167] C4. The method according to any one of embodiments C1 to C3, wherein the method further comprises:

[0168] Filling the plurality of battery cells.

[0169] D1. A method for assembling a battery, the battery comprising a plurality of battery cells and a terminal assembly, the terminal assembly comprising one or more straps and one or more terminals, the method comprising one or more of the following:

[0170] Casting the one or more straps without the one or more terminals;

[0171] Performing inter-cell welding of two or more cells among the multiple cells, the performed inter-cell welding electrically connecting at least one of the one or more tapes without terminals to at least two of the multiple cells; and

[0172] Welding and / or casting the one or more terminals to the one or more cast tapes to form the terminal assembly.

[0173] D2. The method according to embodiment D1, wherein casting of the one or more tapes is performed using an overflow mold.

[0174] D3. The method according to any one of embodiments D1 and D2, wherein casting of the one or more terminals includes lead casting of the one or more terminals.

[0175] D4. The method according to any one of embodiments D1 to D3, wherein welding of the one or more terminals is performed using rotary friction welding.

[0176] D5. The method according to any one of embodiments D1 to D4, wherein welding of the one or more terminals includes:

[0177] Welding the one or more terminals using a resistance welding process.

[0178] Those skilled in the art will understand that this embodiment may not be limited to what may have been particularly shown and described. Additionally, unless the contrary is mentioned above, it should be noted that all the drawings may not be drawn to scale. Various modifications and variations may be possible in accordance with the above teachings and the appended claims.

Claims

1. A method for assembling a battery (10), the battery (10) having a plurality of battery cells (14), a plurality of straps (16) and a plurality of terminals (18), the method comprising: coupling (S1000) each of the plurality of straps (16) to one of the plurality of battery cells (14); coupling (S1002) each of the plurality of terminals (18) to one of the plurality of straps (16), each coupled terminal (18) being electrically coupled to one battery cell (14) corresponding to the one strap (16); and performing (S1004) an inter-cell coupling between at least a pair of the plurality of battery cells (14) by coupling a pair of the plurality of terminals (18).

2. The method according to claim 1, wherein Performing the coupling of each of the plurality of straps (16) to one of the plurality of battery cells (14) using a first strap casting COS process.

3. The method according to any one of claims 1 and 2, wherein Performing the coupling of each of the plurality of terminals (18) to one of the plurality of straps (16) using a second COS process.

4. The method according to any one of claims 1 to 3, wherein The method further comprises, before coupling each strap (16) to a battery cell (14) and coupling each terminal (18) to a strap (16), performing one of the following: filling the battery cells (14); and pre-filling the battery cells (14).

5. The method according to any one of claims 1 to 4, wherein, Performing the inter-cell coupling comprises: welding the pair of terminals (18).

6. The method according to any one of claims 1 to 5, wherein Performing the inter-cell coupling comprises: electrically coupling the pair of terminals (18) to one of the plurality of straps (16).

7. The method according to any one of claims 1 to 6, wherein Performing the inter-cell coupling comprises: coupling one of the plurality of straps (16) to the pair of battery cells (14).

8. The method according to any one of claims 1 to 7, wherein The battery at least comprises an inter-cell connector (204), and performing the inter-cell coupling comprises: coupling the inter-cell connector (204) to the pair of terminals (18).

9. The method according to claim 8, wherein, The battery (10) further comprises a cover (20, 200), the cover (20, 200) comprising a pair of openings (202) electrically coupled via the inter-cell connector (204), and the method further comprises: inserting the pair of terminals (18) through the pair of openings (202), the inserted pair of terminals (18) being electrically coupled via the inter-cell connector (204).

10. The method according to any one of claims 1 to 9, wherein The battery (10) is a lead-acid battery.

11. A method for assembling a battery (10), the battery (10) having a plurality of battery cells (14), a plurality of straps (16) and a plurality of terminals (18), the method comprising: Couple (S1100) each of the plurality of straps (16) to one of the plurality of battery cells (14), and perform coupling each of the plurality of straps (16) to one of the plurality of battery cells (14) using a first strap casting COS process; Couple (S1102) each of the plurality of terminals (18) to one of the plurality of straps (16), with each coupled terminal (18) being electrically coupled to one battery cell (14) corresponding to the one strap (16), and perform coupling each of the plurality of terminals (18) to one of the plurality of straps (16) using a second COS process; And Perform (S1104) inter-cell coupling between at least a pair of the plurality of battery cells (14) by coupling a pair of the plurality of terminals (18).

12. The method according to claim 11, wherein, The method further includes: before coupling each strap (16) to one battery cell (14) and coupling each terminal (18) to one strap (16), performing one of the following: Filling the battery cells (14); and Pre-filling the battery cells (14).

13. The method according to any one of claims 11 and 12, wherein Performing the inter-cell coupling includes: Welding the pair of terminals (18).

14. The method according to any one of claims 11 to 13, wherein Performing the inter-cell coupling includes: Electrically coupling the pair of terminals (18) to one of the plurality of straps (16).

15. The method according to any one of claims 11 to 14, wherein Performing the inter-cell coupling includes: Coupling one of the plurality of straps (16) to the pair of battery cells (14).

16. The method according to any one of claims 11 to 15, wherein The battery (10) includes at least an inter-cell connector (204), and performing the inter-cell coupling includes: Coupling the inter-cell connector (204) to the pair of terminals (18).

17. The method according to claim 16, wherein, The battery (10) further includes a cover (20, 200), the cover (20, 200) including a pair of openings (202) electrically coupled via the inter-cell connector (204), and the method further includes: Inserting the pair of terminals (18) through the pair of openings (202), with the inserted pair of terminals (18) being electrically coupled via the inter-cell connector (204).

18. A method for assembling a battery (10) having a plurality of battery cells (14), a plurality of straps (16), a plurality of terminals (18), and an inter-cell connector (204), the method including: Couple (S1200) each of the plurality of straps (16) to one of the plurality of battery cells (14), and perform coupling each of the plurality of straps (16) to one of the plurality of battery cells (14) using a first strap casting COS process; Couple (S1202) each of the plurality of terminals (18) to one of the plurality of straps (16), each coupled terminal (18) being electrically coupled to one battery cell (14) corresponding to the one strap (16), and perform coupling each of the plurality of terminals (18) to one of the plurality of straps (16) using a second COS process; and perform (S1204) inter-cell coupling between at least a pair of the plurality of battery cells (14) by coupling a pair of the plurality of terminals (18), performing the inter-cell coupling including at least one of the following: welding the pair of terminals (18); electrically coupling the pair of terminals (18) to one of the plurality of straps (16); coupling one of the plurality of straps (16) to the pair of battery cells (14); and coupling the inter-cell connector (204) to the pair of terminals (18).

19. The method according to claim 18, wherein, The method further includes: performing one of the following before coupling each strap (16) to one battery cell (14) and coupling each terminal (18) to one strap (16): filling the battery cell (14); and pre-filling the battery cell (14).

20. The method according to any one of claims 18 and 19, wherein The battery (10) further includes a cover (20, 200), the cover (20, 200) including a pair of openings (202) electrically coupled via the inter-cell connector (204), and the method further includes: inserting the pair of terminals (18) through the pair of openings (202), the inserted pair of terminals (18) being electrically coupled via the inter-cell connector (204).

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