Smart battery manufacturing method

Abstract

A method for assembling a battery is described. The battery has a housing, a post assembly, a plurality of battery cells, and a first cover. The binding post assembly comprises a plurality of binding posts. The first cover has a plurality of first openings. The method includes assembling a housing, a post assembly, and a plurality of battery cells. The assembling includes: coupling the terminal post assembly to the plurality of battery cells by coupling each terminal post of the plurality of terminal posts to a corresponding battery cell of the plurality of battery cells; and inserting the plurality of battery cells and the terminal assembly into the housing. The method further includes coupling the first cover to the housing. At least one of the plurality of terminals protrudes through at least one of the plurality of first openings and protrudes from the first cover.

Description

Technical Field

[0001] The present disclosure relates to batteries and, in particular, to the manufacture and / or assembly of intelligent batteries that contribute to 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 means for performance and fault monitoring. More specifically, existing lead-acid battery systems may not provide one or more battery parameters (e.g., usable to determine performance and / or predict / monitor faults) of one or more battery cells of the lead-acid battery system. In other words, existing lead-acid battery systems have difficulty providing 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 for manufacturing and / or assembling an intelligent battery. In some embodiments, the method may include one or more of the following: assembling a housing and one or more battery cells; performing at least one of charging and shaping the battery; and performing at least one of a first electronic assembly and a second electronic assembly. In some other embodiments, a battery management system (BMS) is connected to one or more components of a lead assembly that can be connected to one or more terminals and / or battery cells to, for example, determine / measure at least one parameter, such as battery cell voltage, current, temperature, etc. In some embodiments, for example, without having to change one or more specifications of the battery, the BMS, lead assembly, terminals, and / or sleeves are assembled / manufactured in the battery.

[0004] According to one aspect, a method for assembling a battery is described. The battery has a housing, a terminal assembly, a plurality of battery cells, and a first cover. The terminal assembly includes a plurality of terminals. The first cover has a plurality of first openings. The method includes assembling the housing, the terminal assembly, and the plurality of battery cells. The assembly includes: coupling the terminal assembly to the plurality of battery cells by coupling each of the plurality of terminals to a corresponding battery cell of the plurality of battery cells; and inserting the plurality of battery cells and the terminal assembly into the housing. The method further includes coupling the first cover to the housing. At least one of the plurality of terminals protrudes through at least one of the plurality of first openings and extends out of the first cover.

[0005] In some embodiments, the method further includes performing charging of the battery.

[0006] In some other embodiments, the first cover further includes a plurality of second openings, and performing the loading of the battery includes inserting one or more bottles into one or more of the plurality of second openings and discharging the bottle contents into the housing.

[0007] In some embodiments, performing the loading of the battery further includes removing one or more bottles and covering the plurality of second openings.

[0008] In some other embodiments, the battery further includes a lead assembly, and the method further includes at least one of the following: placing the lead assembly on the first cover; and coupling the lead assembly to at least one of a plurality of terminals.

[0009] In some embodiments, the battery further includes a battery management system (BMS) and one or more terminals. The method further includes placing the BMS on the battery and coupling the BMS to at least one of the one or more terminals and to the lead assembly.

[0010] In some other embodiments, the lead assembly includes a plurality of leads, each lead including a first end and a second end opposite the first end, and coupling the lead assembly to at least one terminal includes coupling the first end of at least one lead to at least one terminal, and coupling the BMS to the lead assembly includes coupling the second end of at least one lead to the BMS.

[0011] In some embodiments, the battery further includes a wire harness and a vehicle connector, and the method further includes connecting the wire harness to the BMS and the vehicle connector.

[0012] In some other embodiments, the battery further includes a second cover, and the method further includes coupling the second cover to the first cover.

[0013] In some embodiments, the battery further includes a third cover and one or more terminal caps. The second cover includes an access opening. The method further includes at least one of the following: coupling the third cover to the second cover, wherein the third cover covers the access opening of the second cover; sealing the third cover to the second cover; and coupling one or more terminal caps to the first cover.

[0014] In some other embodiments, the battery is a lead-acid battery.

[0015] According to one aspect, a method for assembling a battery is described. The battery has a housing, a terminal assembly, a plurality of battery cells, a lead assembly, and a first cover. The terminal assembly includes a plurality of terminals. The first cover has a plurality of first openings. The method includes assembling the housing, the terminal assembly, and one or more battery cells, wherein the assembling includes: coupling the terminal assembly to the plurality of battery cells by coupling each of the plurality of terminals to a corresponding battery cell of the plurality of battery cells; and inserting the plurality of battery cells and the terminal assembly into the housing. The method further includes coupling the first cover to the housing. At least one of the plurality of terminals protrudes through at least one of the plurality of first openings and extends out from the first cover. Additionally, the lead assembly is coupled to at least one of the plurality of terminals.

[0016] In some embodiments, the method further includes performing a charge of the battery.

[0017] In some other embodiments, the first cover further includes a plurality of second openings, and performing a charge of the battery includes at least one of the following: inserting one or more bottles into one or more of the plurality of second openings; discharging the bottle contents into the housing; removing one or more bottles; and covering the plurality of second openings.

[0018] In some embodiments, the battery further includes a battery management system (BMS) and one or more terminals. The method further includes placing the BMS on the battery and coupling the BMS to at least one of the one or more terminals and coupling to the lead assembly.

[0019] In some other embodiments, the lead assembly includes a plurality of leads, each lead including a first end and a second end opposite the first end, and coupling the lead assembly to at least one terminal includes coupling the first end of at least one lead to at least one terminal, and coupling the BMS to the lead assembly includes coupling the second end of at least one lead to the BMS.

[0020] In some embodiments, the battery further includes a wiring harness and a vehicle connector, and the method further includes connecting the wiring harness to the BMS and the vehicle connector.

[0021] In some other embodiments, the battery further includes a second cover, and the method further includes coupling the second cover to the first cover.

[0022] In some embodiments, the battery further includes a third cover and one or more terminal caps, the second cover includes an access opening, and the method further includes at least one of the following: coupling the third cover to the second cover, wherein the third cover covers the access opening of the second cover; sealing the third cover to the second cover; and coupling one or more terminal caps to the first cover.

[0023] According to one aspect, a method for assembling a battery is described. The battery has a housing, a terminal assembly, a plurality of battery cells, a lead assembly, a battery management system (BMS), one or more terminals, and a first cover. The terminal assembly includes a plurality of terminals. The first cover has a plurality of first openings. The method includes assembling the housing, the terminal assembly, and the plurality of battery cells. The assembling includes: coupling the terminal assembly to the plurality of battery cells by coupling each of the plurality of terminals to a corresponding battery cell of the plurality of battery cells; and inserting the plurality of battery cells and the terminal assembly into the housing. The method further includes coupling the first cover to the housing, wherein at least one of the plurality of terminals protrudes through at least one of the plurality of first openings and extends out from the first cover. Additionally, the method includes: placing the lead assembly on the first cover; coupling the lead assembly to at least one of the plurality of terminals; and coupling the BMS to at least one of the one or more terminals and to the lead assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] A more complete understanding of the embodiments described herein and 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: 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; 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; Figure 3 An example battery manufacturing process in accordance with the principles of the present disclosure is shown; Figure 4 An example battery manufacturing process including an assembly step in accordance with the principles of the present disclosure is shown; Figure 5 An example battery manufacturing process including other assembly steps in accordance with the principles of the present disclosure is shown; Figure 6 An example battery manufacturing process including filling and forming steps in accordance with the principles of the present disclosure is shown; Figure 7 An example battery manufacturing process including an electronic assembly step in accordance with the principles of the present disclosure is shown; Figure 8 An example battery manufacturing process including other electronic assembly steps in accordance with the principles of the present disclosure is shown; Figure 9 An example battery manufacturing process including some other electronic assembly steps in accordance with the principles of the present disclosure is shown; Figure 10Illustrates an example battery manufacturing process including a lid assembly step according to the principles of the present disclosure; Figure 11 Illustrates an example battery manufacturing process including other lid assembly steps according to the principles of the present disclosure; Figure 12 Illustrates another example battery manufacturing process including some assembly steps according to the principles of the present disclosure; Figure 13 Illustrates another example battery manufacturing process including filling and forming steps according to the principles of the present disclosure; Figure 14 Illustrates another example battery manufacturing process including an electronic assembly step according to the principles of the present disclosure; Figure 15 Illustrates another example battery manufacturing process including other electronic assembly steps according to the principles of the present disclosure; Figure 16 Illustrates another example battery manufacturing process including some other electronic assembly steps according to the principles of the present disclosure; Figure 17 Illustrates another example battery manufacturing process including a lid assembly step according to the principles of the present disclosure; Figure 18 Illustrates example assembly steps of an example battery manufacturing process according to the principles of the present disclosure; Figure 19 Illustrates an example method of assembling a battery according to some embodiments of the present disclosure; Figure 20 Illustrates an example method of assembling a battery according to some embodiments of the present disclosure; and Figure 21 Illustrates an example method of assembling a battery according to some embodiments of the present disclosure. Detailed Description

[0025] With the development of battery technology, there is a need to provide improved power supplies and more efficient and cost-effective methods for manufacturing such power supplies compared to conventional systems and methods.

[0026] Accordingly, the embodiments described and illustrated herein provide a battery and a method of assembling the battery that allow for the integration of intelligent features within the battery. In some embodiments, the battery can have the same general shape and form as a battery that does not provide "intelligent" battery features (such as, by way of non-limiting example, the ability to monitor the voltage of individual battery cells). In some embodiments, at least one lead to a corresponding battery cell can be connected to a battery management system (BMS) to, for example, determine / measure at least one parameter such as battery cell voltage, battery cell current, battery cell temperature, etc.

[0027] Figure 1 and Figure 2 illustrates 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 battery cells 14, a terminal assembly 15 (e.g., a cast-on-strap (COS) terminal assembly), one or more straps 16, one or more terminals 18 (e.g., terminal posts, small terminals), 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 (BMS) 26 (e.g., including a board), one or more fasteners 28, a second cover 30, a wire harness 32, a vehicle connector 34, a third cover 36, and one or more terminal caps 38. The terminal assembly 15 may include one or more straps 16 coupled to one or more terminals 18. In some embodiments, the housing 12 may be referred to as an enclosure.

[0028] Figure 3 illustrates an example battery manufacturing process (i.e., method) in accordance with the principles of the present disclosure. The method includes one or more of the following: assembling (block S100) the housing 12 and one or more battery cells 14; performing (block S102) at least one of filling and shaping the battery 10; and performing (block S104) at least one of a first electronic assembly and a second electronic assembly.

[0029] Figure 4 illustrates an example battery manufacturing process including an assembly step. At step S200, one or more battery cells 14 are provided. The battery cells 14 may include a terminal assembly 15. The terminal assembly 15 may be arranged to provide an electrical / physical connection between at least one battery cell 14 and at least one terminal 18. The battery cells 14 may be inserted into the housing 12. The housing 12 may include one or more partitions 17, and the one or more partitions may define volumes between the respective partitions 17. Inserting the battery cells 14 may include inserting one or more battery cells 14 between one or more partitions 17, i.e., where each battery cell 14 is received in a volume defined by two consecutive partitions 17.

[0030] Figure 5Shows additional assembly steps of an example battery manufacturing process in accordance with the principles of the present disclosure. The process may include placing and / or securing a first lid 20 on a housing 12 at step S202. The lid 20 may be aligned with at least one edge of the housing 12. The terminal 18 may be arranged to project through an opening of the first lid 20 and extend away from the first lid 20. Securing the first lid 20 to the housing 13 may include sealing the first lid 20 to the housing 12 and / or a separator 17 such that, for example, the battery cell 14 is housed in a sealed space. Step S202 may be performed after step S200. In some embodiments, step S200 and / or S202 may be Figure 3 part of S100.

[0031] Figure 6 Shows example filling and forming steps of an example battery manufacturing process in accordance with the principles of the present disclosure. At step S204, a sleeve 22 may be coupled to the terminal 18 ( Figure 5 as shown), which may also prevent fluid communication between the external environment and the interior of the housing 12. Further, one or more bottles 21 may be inserted into one or more lid openings 44, and / or the contents of the bottles 21 (e.g., an electrolyte such as sulfuric acid) may be discharged (e.g., released, poured, etc.) into the housing 12 and / or the battery cell 14 and / or Figure 4 the volume defined by the pairs of separators 17 as shown. Step S204 may further include removing the bottles 21 and / or placing a lid 52 in-process on the first lid 20. Placing the lid 52 in-process on the first lid 20 may include covering and / or sealing the opening 44, for example, to isolate the contents of the housing 12 (e.g., the electrolyte and / or the battery cell 14) from the external environment to prevent the electrolyte from spilling out of the housing 12, prevent substances from entering the interior of the housing 12 while the battery 10 is being manufactured, etc. Step S204 may be performed after step S202. In some embodiments, step S204 may be Figure 3 part of step S102. It should be understood that other arrangements may be used to distribute the electrolyte into the interior of the housing 12 and / or the volume defined by the separators 17, such as using a hose / tube / funnel, etc. to distribute the electrolyte into the interior of the housing 12 and / or the volume defined by the separators 17.

[0032] Figure 7Illustrates an example electronic assembly step of an example battery manufacturing process in accordance with the principles of the present disclosure. At step S206, the lead assembly 24 can be placed on the first cover 20 and / or connected to at least one sleeve 22 and / or terminal post 18. Placing the lead assembly 24 on the first cover 20 and / or connecting the lead assembly 24 to at least one sleeve 22 and / or terminal post 18 can include aligning the lead assembly 24 with one or more components of the battery 10 (e.g., the sleeve 22), and / or inserting (and / or coupling) one or more portions of the lead assembly 24 into one or more components of the battery 10 (e.g., the first cover 20), and / or vice versa. The lead assembly 24 can be arranged to be coupled (e.g., electrically / physically coupled) to a plurality of sleeves 22 and a plurality of terminal posts 18 ( Figure 4 as shown) and the battery cell 14 ( Figure 4 as shown). More specifically, the lead assembly 24 can include a plurality of leads 25, where each lead 25 has a first end and a second end opposite the first end. The first end of each lead 25 can be arranged to establish a physical and / or electrical connection with the BMS 26 via the sleeve 22, the terminal post 18, etc., and the second end establishes a physical and / or electrical connection with the battery cell 14. Step S206 can be performed after step S204. In some embodiments, step S206 can be Figure 3 part of step S104 of

[0033] Figure 8 Illustrates other electronic assembly steps of an example battery manufacturing process in accordance with the principles of the present disclosure. At step S208, the BMS 26 is connected to one or more components of the battery 10. Connecting the BMS 26 to one or more components of the battery 10 can include placing the BMS 26 on the lead assembly 24 and / or connecting the BMS 26 to: the terminal 40 (e.g., the negative terminal) of the battery 10, with connection using the fastener 28 and the bus bar 48; one or more components of the lead assembly 24 (e.g., the lead 25 of the lead assembly 24, the BMS connector of the lead assembly 24, etc.); and / or any other component to form an electrical / physical connection. In this non-limiting example, the BMS 26 can be electrically connected (e.g., using one fastener 28 and the bus bar 48) to the negative terminal of the battery 10, and physically / mechanically coupled (using another bus bar 48 and another fastener 28 that has been coupled to the first cover 20) to the first cover 20. Step S208 can be performed after step S206. In some embodiments, step S208 can be Figure 3 part of step S104 of

[0034] Figure 9Shows some additional electronic assembly steps of an example battery manufacturing process in accordance with the principles of the present disclosure. At step S210, the cover 52 in the process flow may be removed and / or a second cover 30 may be coupled to or sealed to the first cover 20 of the battery 10. The second cover 30 may have an access opening 80 that is arranged to provide access to the interior of the second cover 30 (e.g., to access the BMS 26, the lead assembly 24, etc.). The harness 32 may be connected to the BMS 26, for example, using the braided tail of the harness 32 and / or the vehicle connector 34. Step S210 may be performed after step S208. In some embodiments, step S210 may be Figure 3 part of step S104 of

[0035] Figure 10 Shows an example cover assembly step of an example battery manufacturing process in accordance with the principles of the present disclosure. At step S212, a third cover 36 may be coupled to the second cover 30 (and / or the access opening 80). Coupling the third cover 36 to the second cover 30 (and / or the access opening 80) may include sealing the third cover 36 to the second cover 30 (and / or the access opening 80) using a heating process such as laser welding. Step S212 may be performed after step S210. In some embodiments, step S212 may be Figure 3 part of step S104 of

[0036] Figure 11 Shows other cover assembly steps of an example battery manufacturing process in accordance with the principles of the present disclosure. At step S214, one or more terminal caps 38 are coupled to the first cover 20, which may include covering one or more terminal posts 42 ( Figure 10 as shown). Step S214 may be performed after step S212. In some embodiments, step S214 may be Figure 3 part of step S104 of

[0037] In some embodiments, one or more of the steps described herein may include one or more steps associated with pre-filling, filling, connecting (e.g., cell-to-cell connection based on small posts / posts), welding (e.g., electric fusion welding, cell-to-cell welding), and / or any other steps.

[0038] Figures 12 to 17 Shows another embodiment of the battery manufacturing process. Figures 12 to 17 One or more of the steps shown may be similar and / or corresponding to Figures 5 to 11 one or more of the steps of Figures 12 to 17 Some steps of the example battery manufacturing process associated with Figure 3 may be similar and / or corresponding to other figures (e.g.,

[0039] More specifically, Figure 12 Another exemplary battery manufacturing process including other assembly steps in accordance with the principles of the present disclosure is shown. The process may include placing and / or securing a first lid 20 on the housing 12 at step S300. The lid 20 may be aligned with at least one edge of the housing 12. One or more sleeves 22 may be coupled, for example, coupling one sleeve 22 (a small sleeve) to a corresponding opening in the first lid 20 (and / or the terminal post 18, such as a micro-terminal post) and / or coupling another sleeve 22 (e.g., a U1 sleeve) to another opening in the first lid 20 and the terminal 40 (and corresponding terminal post 18, such as a terminal post). The coupling may include electrical coupling and / or physical coupling. Additionally, the first lid 20 may include one or more lid openings 44. Step S300 may be performed after providing one or more battery cells 14 (e.g., similar to step S200). In some embodiments, step S300 may be Figure 3 part of S100.

[0040] Figure 13 The filling and forming steps of an exemplary battery manufacturing process in accordance with the principles of the present disclosure are shown. At step S302, one or more bottles 21 (i.e., liquid containers) may be inserted into one or more lid openings 44 ( Figure 12 as shown) and / or the contents of the bottle 21 (e.g., an electrolyte, such as sulfuric acid) may be discharged (e.g., dispensed, poured, etc.) into the interior of the housing 12 that houses the battery cells 14. At least one bottle 21 may include a seal 90 (e.g., an O-ring). The seal 90 may be arranged to apply a biasing pressure to the opening 44 when the bottle 21 is inserted into the opening 44 and / or prevent the contents of the bottle from spilling or discharging outside the battery 10. Step S204 may further include removing the bottle 21 and / or placing a lid 53 on the first lid 20. In some embodiments, the lid 53 is a membrane. The membrane may be a barrel-shaped membrane. In a non-limiting example, the barrel-shaped membrane may be a 0.5 mm thick barrel-shaped membrane. However, the barrel-shaped membrane may have any other thickness. Further, the lid 53 may be shaped to conform to the shape of the opening 44, e.g., having a disk shape that conforms to the circular shape of the opening 44. Placing the lid 53 on the first lid 20 may include covering and / or sealing the opening 44, e.g., to isolate the contents of the housing 12 (e.g., acid) from the outside, to prevent acid from spilling out of the housing 12, to prevent substances from entering the housing 12 during the manufacture of the battery 10, etc. Step S302 may be performed after step S300. In some embodiments, step S302 may be Figure 3 part of step S102.

[0041] Figure 14Shows the electronic assembly steps of an example battery manufacturing process in accordance with the principles of the present disclosure. At step S304, the lead assembly 24 can be placed on the first cover 20 and / or connected to at least one terminal 18. Placing the lead assembly 24 on the first cover 20 and / or connecting the lead assembly 24 to at least one terminal 18 can include aligning the lead assembly 24 with one or more components of the battery 10 (e.g., the terminal 18), and / or inserting (and / or coupling) one or more portions of the lead assembly 24 into one or more components of the battery 10 (e.g., the first cover 20), and / or vice versa. Step S304 can further include coupling the loop 58 of the lead assembly 24 to the corresponding sleeve 22. Step S304 can be performed after step S302. In some embodiments, step S304 can be Figure 3 a part of step S104.

[0042] Figure 15 Shows some other electronic assembly steps of an example battery manufacturing process in accordance with the principles of the present disclosure. At step S306, the BMS 26 is connected to one or more components of the battery 10. Connecting the BMS 26 to one or more components of the battery 10 can include placing the BMS 26 on the lead assembly 24 and / or connecting the BMS 26 to: the terminal 40 of the battery 10 (e.g., the negative terminal), using the fastener 28 and the bus bar 48 for connection; one or more components of the lead assembly 24 (e.g., the leads of the lead assembly 24, the BMS connector of the lead assembly 24, etc.); and / or any other components to form an electrical / physical connection. At least one of the bus bars 48 can be arranged to conform to the terminal shape, and the method can further include aligning the bus bar 48 with the terminal and coupling the bus bar 48 to the terminal. In this non-limiting example, the BMS 26 can be electrically connected to the negative terminal of the battery 10 (e.g., using one fastener 28 and the bus bar 48), and physically / mechanically coupled to the first cover 20 (using another bus bar 48 and another fastener 28 that has been coupled to the first cover 20). Step S306 can be performed after step S304. In some embodiments, step S306 can be Figure 3 a part of step S104.

[0043] Figure 16 Shows some other electronic assembly steps of an example battery manufacturing process in accordance with the principles of the present disclosure. At step S308, the cover 53 can be removed ( Figure 15as shown) and / or the second cover 30 can be coupled to the first cover 20 of the battery 10. A wiring harness 32 (not shown) can be connected to the BMS 26, for example, using a braided tail of the wiring harness 32 and / or a vehicle connector 34. The second cover 30 can include an access opening 80. Step S308 can be performed after step S306. In some embodiments, step S308 can be Figure 3 a part of step S104 of

[0044] Figure 17 FIG. shows an example cover assembly step of an example battery manufacturing process in accordance with the principles of the present disclosure. At step S310, a third cover 36 can be coupled to the second cover 30 (and / or the access opening 80). Coupling the third cover 36 to the second cover 30 (and / or the access opening 80) can include sealing the third cover 36 to the second cover 30 (and / or the access opening 80) using a heating process. At step S310, one or more terminal caps 38 can be coupled to the first cover 20, which can include covering one or more terminal posts 42. Step S310 can be performed after step S308. In some embodiments, step S310 can be Figure 3 a part of step S104 of

[0045] Figure 18 FIG. shows an example assembly step of an example battery manufacturing process in accordance with the principles of the present disclosure. The process can include placing and / or securing a first cover 120 on a housing 112 at step S400. The first cover 120 can include terminals 140a, 140b (collectively referred to as terminals 140). Step S400 can be similar to S202, and the terminals 140 are coplanar with the first cover 120 and can be different from ( Figure 5 the) terminals 40, which include a portion that is not coplanar with the first cover 20. Having coplanar terminals 140 can facilitate reducing the required size of the second cover coupled to the first cover 120.

[0046] Figure 19Illustrates an example method of assembling a battery 10 according to some embodiments of the present disclosure. The battery 10 has a housing 12, a terminal assembly 15, a plurality of battery cells 14, and a first cover 20. The terminal assembly 15 includes a plurality of terminals 18. The first cover 20 has a plurality of first openings. The method includes assembling (block S500) the housing 12, the terminal assembly 15, and the plurality of battery cells 14. The assembling includes: coupling the terminal assembly 15 to the plurality of battery cells 14 by coupling each of the plurality of terminals 18 to a corresponding battery cell 14 of the plurality of battery cells 14; and inserting the plurality of battery cells 14 and the terminal assembly 15 into the housing 12. The method further includes coupling (block S502) the first cover 20 to the housing 12. At least one of the plurality of terminals 18 protrudes through at least one of the plurality of first openings and extends out of the first cover 20.

[0047] In some embodiments, the method further includes performing a filling of the battery 10.

[0048] In some other embodiments, the first cover 20 further includes a plurality of second openings 44, and performing a filling of the battery 10 includes inserting one or more bottles 21 into one or more of the plurality of second openings 44 and discharging the bottle contents into the housing 12.

[0049] In some embodiments, performing a filling of the battery 10 further includes removing the one or more bottles 21 and covering the plurality of second openings 44.

[0050] In some other embodiments, the battery further includes a lead assembly 24, and the method further includes at least one of the following: placing the lead assembly 24 on the first cover 20; and coupling the lead assembly 24 to at least one of the plurality of terminals 18.

[0051] In some embodiments, the battery further includes a battery management system (BMS) 26 and one or more terminals 40. The method further includes placing the BMS 26 on the battery 10 and coupling the BMS 26 to at least one of the one or more terminals and coupling to the lead assembly 24.

[0052] In some other embodiments, the lead assembly 24 includes a plurality of leads 25, each lead 25 including a first end and a second end opposite the first end, and coupling the lead assembly 15 to at least one terminal 18 includes coupling a first end of at least one lead 25 to at least one terminal 18, and coupling the BMS 26 to the lead assembly 24 includes coupling a second end of at least one lead 25 to the BMS 26.

[0053] In some embodiments, the battery 10 further includes a wire harness 32 and a vehicle connector 34, and the method further includes connecting the wire harness 32 to the BMS 26 and the vehicle connector 34.

[0054] In some other embodiments, the battery 10 further includes a second cover 30, and the method further includes coupling the second cover 30 to the first cover 20.

[0055] In some embodiments, the battery 10 further includes a third cover 36 and one or more terminal caps 38. The second cover 30 includes an access opening 80. The method further includes at least one of the following: coupling the third cover 36 to the second cover 30, wherein the third cover 36 covers the access opening 80 of the second cover 30; sealing the third cover 36 to the second cover 30; and coupling one or more terminal caps 38 to the first cover 20.

[0056] In some other embodiments, the battery 10 is a lead-acid battery.

[0057] Figure 20 An example method of assembling a battery 10 in accordance with some embodiments of the present disclosure is shown. The battery 10 has a housing 12, a terminal assembly 15, a plurality of battery cells 14, a lead assembly 24, and a first cover 20. The terminal assembly 15 includes a plurality of terminals 18. The first cover 20 has a plurality of first openings. The method includes assembling (block S600) the housing 12, the terminal assembly 15, and the plurality of battery cells 14. The assembling includes: coupling the terminal assembly 15 to the plurality of battery cells 14 by coupling each of the plurality of terminals 18 to a corresponding one of the plurality of battery cells 14; and inserting the plurality of battery cells 14 and the terminal assembly 15 into the housing 12. The method further includes coupling (block S602) the first cover 20 to the housing 12. At least one of the plurality of terminals 18 projects through at least one of the plurality of first openings and extends from the first cover 20. Additionally, the method includes coupling (block S604) the lead assembly 24 to at least one of the plurality of terminals 18.

[0058] In some embodiments, the method further includes performing a charge of the battery 10.

[0059] In some other embodiments, the first cover 20 further includes a plurality of second openings 44, and performing a charge of the battery 10 includes at least one of the following: inserting one or more bottles 21 into one or more of the plurality of second openings 44; discharging the bottle contents into the housing 12; removing the one or more bottles 21; and covering the one or more second openings 44.

[0060] In some embodiments, the battery further includes a battery management system (BMS) 26 and one or more terminals 40. The method further includes placing the BMS 26 on the battery 10 and coupling the BMS 26 to at least one of the one or more terminals 40 and to the lead assembly 24.

[0061] In some other embodiments, the lead assembly 24 includes a plurality of leads 25, each lead 25 including a first end and a second end opposite the first end, and coupling the lead assembly 15 to at least one terminal 18 includes coupling the first end of at least one lead 25 to at least one terminal 18, and coupling the BMS 26 to the lead assembly 24 includes coupling the second end of at least one lead 25 to the BMS 26.

[0062] In some embodiments, the battery 10 further includes a wire harness 32 and a vehicle connector 34, and the method further includes connecting the wire harness 32 to the BMS 26 and the vehicle connector 34.

[0063] In some other embodiments, the battery 10 further includes a second cover 30, and the method further includes coupling the second cover 30 to the first cover 20.

[0064] In some embodiments, the battery 10 further includes a third cover 36 and one or more terminal caps 38. The second cover 30 includes an access opening 80. The method further includes at least one of the following: coupling the third cover 36 to the second cover 30, wherein the third cover 36 covers the access opening 80 of the second cover 30; sealing the third cover 36 to the second cover 30; and coupling one or more terminal caps 38 to the first cover 20.

[0065] Figure 21Illustrates an example method of assembling a battery 10 in accordance with some embodiments of the present disclosure. The battery 10 has a housing 12, a terminal assembly 15, a plurality of battery cells 14, a lead assembly 24, a battery management system (BMS) 26, one or more terminals 40, and a first cover 20. The terminal assembly 15 includes a plurality of terminals 18. The first cover 20 has a plurality of first openings. The method includes assembling (block S700) the housing 12, the terminal assembly 15, and the plurality of battery cells 14. The assembling includes: coupling the terminal assembly 15 to the plurality of battery cells 14 by coupling each of the plurality of terminals 18 to a corresponding one of the plurality of battery cells 14; and inserting the plurality of battery cells 14 and the terminal assembly 15 into the housing 12. The method further includes coupling (block S702) the first cover 20 to the housing 12. At least one of the plurality of terminals 18 projects through at least one of the plurality of first openings and extends from the first cover 20. Additionally, the method includes: placing (block S704) the lead assembly 24 on the first cover 20; coupling (block S706) the lead assembly 24 to at least one of the plurality of terminals 18; and coupling (block S708) the BMS 26 to at least one of the one or more terminals 40 and the lead assembly 24.

[0066] Embodiments of the present disclosure are beneficial, at least because each battery cell 14 can be electrically coupled to the BMS 26, for example, via the terminal 18, the sleeve 22, the lead 25, etc. That is, the BMS 26 of the assembled battery 10 can be configured to measure at least one parameter of each individual battery cell 14. The BMS 26 can use these parameters to determine the performance of one or more battery cells 14 of the lead acid battery 10 and / or predict / monitor its failure. Further, the state of health of each individual battery cell can be determined and predicted.

[0067] Those skilled in the art will understand that the embodiments may not be limited to what has been particularly shown and described. Additionally, unless the contrary has been mentioned above, it should be noted that all of the figures may not be drawn to scale. Various modifications and variations may be possible in light of the above teachings and the appended claims.

Claims

1. A method for assembling a battery (10), the battery (10) having a housing (12), a terminal assembly (15), a plurality of battery cells (14), and a first cover (20), the terminal assembly (15) including a plurality of terminals (18), the first cover (20) having a plurality of first openings, the method comprising: Assembling (S500) the housing (12), the terminal assembly (15), and the plurality of battery cells (14), the assembling including: Coupling the terminal assembly (15) to the plurality of battery cells (14) by coupling each terminal (18) of the plurality of terminals (18) to a corresponding battery cell (14) of the plurality of battery cells (14); and Inserting the plurality of battery cells (14) and the terminal assembly (15) into the housing (12); and Coupling (S502) the first cover (20) to the housing (12), at least one terminal (18) of the plurality of terminals (18) protruding through at least one of the plurality of first openings and extending from the first cover (20).

2. The method according to claim 1, wherein, The method further comprises: Performing a filling of the battery (10).

3. The method according to claim 2, wherein, The first cover (20) further includes a plurality of second openings (44), and performing a filling of the battery (10) includes: Inserting one or more bottles (21) into one or more of the plurality of second openings (44); and Discharging the bottle contents into the housing (12).

4. The method according to claim 3, wherein Performing a filling of the battery (10) further includes: Removing the one or more bottles (21); and Covering the plurality of second openings (44).

5. The method according to any one of claims 1 to 4, wherein The battery (10) further includes a lead assembly (24), and the method further includes at least one of the following: Placing the lead assembly (24) on the first cover (20); and Coupling the lead assembly (24) to the at least one terminal (18) of the plurality of terminals (18).

6. The method according to claim 5, wherein, The battery (10) further includes a battery management system BMS (26), one or more terminals (40), and the method further includes: Placing the BMS (26) on the battery (10); and Coupling the BMS (26) to at least one of the one or more terminals and coupling to the lead assembly (24).

7. The method according to claim 6, wherein, The lead assembly (24) includes a plurality of leads (25), each lead including a first end and a second end opposite the first end, and coupling the lead assembly (24) to the at least one terminal (18) includes coupling a first end of at least one lead (25) to the at least one terminal (18), and coupling the BMS (26) to the lead assembly (24) includes coupling a second end of the at least one lead (25) to the BMS (26).

8. The method according to any one of claims 6 and 7, wherein The battery (10) further includes a wire harness (32) and a vehicle connector (34), and the method further includes: Connect the harness (32) to the BMS (26) and the vehicle connector (34).

9. The method according to any one of claims 1 to 8, wherein The battery (10) further includes a second cover (30), and the method further includes: Couple the second cover (30) to the first cover (20).

10. The method according to claim 9, wherein, The battery (10) further includes a third cover (36) and one or more terminal caps (38), the second cover (30) includes an access opening (80), and the method further includes at least one of the following: Couple the third cover (36) to the second cover (30), the third cover (36) covering the access opening (80) of the second cover (30); Seal the third cover (36) to the second cover (30); and Couple the one or more terminal caps (38) to the first cover (20).

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

12. A method for assembling a battery (10) having a housing (12), a terminal assembly (15), a plurality of battery cells (14), a lead assembly (24), and a first cover (20), the terminal assembly (15) including a plurality of terminals (18), the first cover (20) having a plurality of first openings, the method: Assemble (S600) the housing (12), the terminal assembly (15), and the one or more battery cells (14), the assembly including: Couple the terminal assembly (15) to the plurality of battery cells (14) by coupling each terminal (18) of the plurality of terminals (18) to a corresponding battery cell (14) of the plurality of battery cells (14); And Insert the plurality of battery cells (14) and the terminal assembly (15) into the housing (12); Couple (S602) the first cover (20) to the housing (12), at least one of the plurality of terminals (18) protruding through at least one of the plurality of first openings and extending from the first cover (20); And Couple (S604) the lead assembly (24) to the at least one of the plurality of terminals (18).

13. The method according to claim 12, wherein, The method further includes: Perform the filling of the battery (10).

14. The method according to claim 13, wherein, The first cover (20) further includes a plurality of second openings (44), and performing the filling of the battery (10) includes at least one of the following: Insert one or more bottles (21) into one or more of the plurality of second openings (44); Discharge the bottle contents into the housing (12); Remove the one or more bottles (21); and Cover the plurality of second openings (44).

15. The method according to any one of claims 12 to 14, wherein The battery (10) further includes a battery management system BMS (26), one or more terminals (40), and the method further includes: Place the BMS (26) on the battery (10); and Couple the BMS (26) to at least one of the one or more terminals (40) and to the lead assembly (24).

16. The method according to claim 15, wherein, The lead assembly (24) includes a plurality of leads (25), each lead (25) having a first end and a second end opposite the first end, and coupling the lead assembly (24) to the at least one terminal (18) includes coupling a first end of at least one lead (25) to the at least one terminal (18), and coupling the BMS (26) to the lead assembly (24) includes coupling a second end of the at least one lead (25) to the BMS (26).

17. The method according to any one of claims 15 and 16, wherein The battery (10) further includes a wire harness (32) and a vehicle connector (34), and the method further includes: Connect the wire harness (32) to the BMS (26) and the vehicle connector (34).

18. The method according to claim 17, wherein, The battery (10) further includes a second cover (30), and the method further includes: Couple the second cover (30) to the first cover (20).

19. The method according to claim 18, wherein, The battery (10) further includes a third cover (36) and one or more terminal caps (38), the second cover (30) includes an access opening (80), and the method further includes at least one of the following: Couple the third cover (36) to the second cover (30), the third cover (36) covering the access opening (80) of the second cover (30); Seal the third cover (36) to the second cover (30); and Couple the one or more terminal caps (38) to the first cover (20).

20. A method for assembling a battery (10) having a housing (12), a terminal assembly (15), a plurality of battery cells (14), a lead assembly (24), a battery management system BMS (26), one or more terminals (40), and a first cover (20), the terminal assembly (15) including a plurality of terminals (18), the first cover (20) having a plurality of first openings, the method comprising: Assemble (S700) the housing (12), the terminal assembly (15), and the one or more battery cells (14), the assembly including: Couple the terminal assembly (15) to the plurality of battery cells (14) by coupling each of the plurality of terminals (18) to a corresponding one of the plurality of battery cells (14); and Insert the plurality of battery cells (14) and the terminal assembly (15) into the housing (12); Couple (S702) the first cover (20) to the housing (12), at least one of the plurality of terminals (18) protruding through at least one of the plurality of first openings and extending from the first cover (20); Place (S704) the lead assembly (24) on the first cover (20); Couple the lead assembly (24) to at least one of the plurality of terminals (18) (S706); and Couple the BMS (26) to at least one of the one or more terminals (40) and to the lead assembly (24).

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