Sensing connection method

Abstract

A lead connection for coupling a first end of a lead (50) to a terminal post (18) and a bushing (22) of a battery is described. The lead connection includes a first weld seam (40, 42) including a bushing and a post welded to the bushing. The lead connection also includes a second weld (70, 72). The second weld includes a first weld and a first end of the lead. At least a portion of the first weld is distributed around and over the first end of the lead to electrically couple the first end of the lead to the bushing and the post.

Description

Technical Field

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

[0002] As battery technology advances, 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 performance and fault monitoring pathways and have complex venting arrangements. More specifically, existing lead-acid battery systems may be unable to provide one or more battery parameters (e.g., that can be used to determine performance and / or predict / monitor faults) for 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 state of health of individual battery cells. Consequently, the inability to monitor and / or determine the state of health of the battery cells hinders the ability to predict an impending battery failure or the onset of a failure. Summary of the Invention

[0003] Some embodiments advantageously provide a connection (and / or method of making a connection) for sensing parameters associated with a battery cell and / or battery. In some embodiments, the method of making a connection is a sensing connection method.

[0004] According to one aspect, a lead assembly connection for coupling a terminal connector of a lead assembly is described. The lead assembly connection includes a first weld comprising a bushing and a terminal welded to the bushing. The lead assembly connection further includes a second weld comprising the first weld and the terminal connector. At least a portion of the first weld is disposed around and above the terminal connector to electrically couple the terminal connector to the bushing and the terminal.

[0005] According to another aspect, a battery is described. The battery includes a housing for housing a battery cell, wherein the battery cell includes a terminal electrically coupled to the battery cell. Furthermore, the battery includes a cover sealed to the housing and including a bushing coupled to the cover. The cover, sealed to the housing, defines an interior space of the housing. The terminal is inserted through the bushing. At least a portion of the terminal protrudes from the bushing and is exterior to the interior space of the housing. The battery further includes a first weld, a lead assembly, and a second weld. The first weld includes a bushing and a terminal welded to the bushing. The lead assembly includes a terminal connector. The second weld includes a first weld welded to the terminal connector. At least a portion of the first weld is distributed around and above the terminal connector to electrically couple the terminal connector to the bushing, the terminal, and the battery cell. One or more of the first weld and the second weld seal the terminal and bushing to the cover. The second weld is exterior to the interior space of the housing.

[0006] According to one aspect, a lead connection for coupling a first end of a lead to a terminal and a bushing of a battery is described. The lead connection includes a first weld, the first weld comprising the bushing and the terminal welded to the bushing. The lead connection also includes a second weld, the second weld comprising the first weld and the first end of the lead. At least a portion of the first weld extends around and over the first end of the lead to electrically couple the first end of the lead to the bushing and the terminal.

[0007] In some embodiments, the first weld is a weld button extending from the terminal.

[0008] In some other embodiments, the welding button includes a first portion and a second portion adjacent to the first portion, and the second portion is a curved structure.

[0009] In some embodiments, the first end of the lead is positioned between the first portion and the second portion and is physically coupled to the terminal.

[0010] In some other embodiments, the first weld has a third portion covering the terminal and in physical contact with the terminal.

[0011] In some embodiments, the first weld and the second weld are integrated into a unitary construction.

[0012] In some other embodiments, the first end of the lead is one of a ring and a terminal connector.

[0013] In some embodiments, the first weld and the second weld may be electrically connected to the battery cell via terminals, and the leads may be connected to a battery management system (BMS), which may be configured to measure battery parameters via the lead connections.

[0014] According to another aspect, a battery is described. The battery includes a housing, a cover, a plurality of terminals, and a plurality of leads. The housing houses a plurality of battery cells. Each of the plurality of terminals is electrically coupled to at least one battery cell from the plurality of battery cells. The cover is sealed to the housing and includes a plurality of bushings coupled to the cover. Each of the plurality of terminals is inserted through a corresponding bushing. The plurality of leads includes a plurality of lead connections. Each lead includes a first end and a second end opposite the first end. Each of the plurality of lead connections includes a first weld and a second weld. The first weld includes one of the bushings and one of the plurality of terminals. The one terminal is welded to the one bushing. The second weld includes the first weld and the first end of the lead. At least a portion of the first weld is distributed around and above the first end of the lead to electrically couple the first end of the lead to the bushing and the terminal.

[0015] In some embodiments, the cover sealed to the housing defines an interior space of the housing for housing the plurality of battery cells, and the leads are connected outside the interior space of the housing.

[0016] In some other embodiments, the battery further includes a battery management system (BMS) configured to measure a battery parameter via each of the plurality of lead connections. The BMS is electrically coupled to the second end of each lead.

[0017] In some embodiments, the first weld is a weld button extending away from the cover.

[0018] In some other embodiments, the welding button includes a first portion and a second portion adjacent to the first portion, wherein the first portion is adjacent to the cover, and the second portion is a curved structure.

[0019] In some embodiments, the first weld has a third portion covering and in physical contact with the one post.

[0020] In some other embodiments, the first weld and the second weld are integrated into a single unitary construction.

[0021] In some embodiments, the first end of each lead is one of a ring and a terminal connector.

[0022] According to one aspect, a method for coupling a first end of a lead to a terminal and a bushing of a battery is described. The battery includes a cover. The bushing is coupled to the cover. The method includes inserting the terminal through the bushing, wherein at least a portion of the terminal protrudes from the bushing and the cover; and performing a first weld by welding the terminal to the bushing. The weld is applied to at least the portion of the terminal protruding from the bushing. The method also includes performing a second weld by welding the first weld to the first end of the lead. At least another portion of the first weld is distributed around and above the first end of the lead.

[0023] In some embodiments, performing the first weld includes forming a weld button that extends away from the cover.

[0024] In some other embodiments, the welding button includes a first portion and a second portion adjacent to the first portion. The second portion is a curved structure.

[0025] In some embodiments, the method further includes positioning a first end of the lead between the first portion and the second portion, and coupling the first end to the post and the bushing.

[0026] In some other embodiments, the first weld has a third portion covering the terminal.

[0027] In some embodiments, the method further includes integrating the first weld and the second weld into a single unitary construction.

[0028] In some other embodiments, the first end of the lead is one of a ring and a terminal connector.

[0029] In some embodiments, the battery further includes a battery management system (BMS) that can be configured to measure a battery parameter via the first end of the lead, the first weld, and the second weld. The lead further includes a second end opposite the first end, and the method further includes coupling the second end of the lead to the BMS. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] A more complete understanding of the embodiments described herein and their attendant advantages and features will be more readily appreciated by reference to the following detailed description considered in conjunction with the accompanying drawings, in which:

[0031] Figure 1 An example battery and one or more components of an example battery according to the principles of the present disclosure are shown;

[0032] Figure 2 An example battery (e.g., exploded view) and one or more components of an example battery are shown according to principles of the present disclosure;

[0033] Figure 3 An example housing and cover including a bushing according to the principles of the present disclosure are shown;

[0034] Figure 4 shows an example first cover coupled to a housing according to the principles of the present disclosure;

[0035] Figure 5 An example terminal and bushing according to the principles of the present disclosure are shown;

[0036] Figure 6 Another example terminal and bushing according to the principles of the present disclosure is shown;

[0037] Figure 7 An example weld according to the principles of the present disclosure is shown;

[0038] Figure 8 The present invention is shown in accordance with the principles of the present invention. Figure 7 A view of an example weld;

[0039] Figure 9 The present invention is shown in accordance with the principles of the present invention. Figure 8 Cross-sectional view of an example weld;

[0040] Figure 10 The present invention is shown in accordance with the principles of the present invention. Figure 7 View of the example weld shown;

[0041] Figure 11 The present invention is shown in accordance with the principles of the present invention. Figure 10 Cross-sectional view of an example weld;

[0042] Figure 12 shows an example of multiple leads according to the principles of the present disclosure;

[0043] Figure 13 An example lead assembly according to the principles of the present disclosure is shown;

[0044] Figure 14 Another example of multiple leads according to the principles of the present disclosure is shown;

[0045] Figure 15 Another example of a lead assembly according to the principles of the present disclosure is shown;

[0046] Figure 16 shows example lead assemblies and welds according to the principles of the present disclosure;

[0047] Figure 17 An example weld according to the principles of the present disclosure is shown;

[0048] Figure 18 Another example weld according to the principles of the present disclosure is shown;

[0049] Figure 19 An example weld according to the principles of the present disclosure is shown;

[0050] Figure 20 Another example weld according to the principles of the present disclosure is shown;

[0051] Figure 21 A flowchart illustrating an example lead connection process according to the principles of the present disclosure; and

[0052] Figure 22 A flow chart illustrating an example wire connection process according to the principles of the present disclosure is shown. DETAILED DESCRIPTION

[0053] As battery technology advances, a need exists to provide improved power sources, as well as more efficient and cost-effective methods for manufacturing and / or assembling such power sources, as compared to conventional systems and methods.

[0054] Thus, the embodiments described and illustrated herein provide a method of manufacturing and / or assembling a smart battery (e.g., a sensing connection method, a lead and / or lead assembly connection method, a method for connecting bushings, terminals, and leads to a lead frame).

[0055] In some embodiments, the term "smart battery" may be used and may refer to a battery having, for example, lead, lithium, or sodium chemistries that are enabled by electronics physically attached to the battery to monitor battery functional parameters, such as, but not limited to, state of charge, state of health, and / or trends thereof, or to transmit battery conditions from within or outside the battery environment. The electronics may generally be referred to as connected electronics and may include a battery management system or any other electronic components. Further, the electronics may utilize a wired or wireless transmission device or communication interface that is configured to transmit data and / or information, such as, applicable battery information and / or derivatives of battery information.

[0056] In some other embodiments, the term "connect" or "connection" may refer to physically and / or electrically connecting (e.g., coupling) one or more components. In some embodiments, the term "connector" is used and may refer to two or more components of a battery that are coupled to each other. A connector may also include two or more components that are welded or coupled using any other coupling mechanism or process. In some other embodiments, a connector may be referred to as a weld, such as a formed component produced by welding two or more components together. The weld may include at least a first portion and a second portion adjacent to the first portion. The first portion may be a top portion, and the second portion may be a side portion. The first portion and / or the second portion may be referred to as a weld button and may extend from another component (such as a battery cover) and be accessible and / or exposed to accommodate other components to which the weld button may be additionally coupled (welded).

[0057] Figure 1 and Figure 2 An example battery (e.g., a lead-acid battery with an intelligent absorbent glass mat (AGM) battery assembly) and one or more components of the example battery are shown. 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 terminals, miniature terminals), a first cover 20, one or more bushings 22 (e.g., U1 bushings, miniature bushings), a lead assembly 24 (e.g., a lead frame), a battery management system (BMS) 26 (e.g., including a plate), one or more fasteners 28, a second cover 30, a wiring harness 32, a vehicle connector 34, a third cover 36, and one or more terminal caps 38. Terminal assembly 15 may include one or more straps 16 coupled to one or more terminals 18. In some embodiments, housing 12 may be referred to as a housing.

[0058] Figure 3 An example housing 12 and a first cover 20 including a bushing 22 are shown in accordance with the principles of the present disclosure. More specifically, the battery cell 14 ( Figure 2 ) has been inserted into the housing 12. The battery cells 14 (via Figure 2 The terminal assembly 15 shown is connected to the terminal 18. The first cover 20 includes one or more bushings 22, such as bushing 22a (e.g., a miniature bushing) and bushing 22b. Bushing 22a is aligned with terminal 18a, and bushing 22b is aligned with terminal 18b. Other bushings 22 can be aligned with other terminal 18. The first cover 20 is then coupled (and / or sealed) to the housing 12.

[0059] Figure 4 The first cover 20 is shown coupled to the housing 12. More specifically, the first cover 20 is shown coupled to the housing 12 wherein the terminals 18 may be in contact with their respective bushings 22 and wherein at least a portion of the terminals 18 protrude from the respective bushings 22, as shown. Figure 5 and Figure 6 As shown. Figure 5 In FIG, the terminal 18a has been inserted through the bushing 22a, wherein the terminal 18a can be in direct contact with the bushing 22a and a portion of the terminal 18a protrudes from the bushing 22a. Figure 6 In FIG. 1 , the terminal 18 b has been inserted through the bushing 22 b , wherein the terminal 18 b may be in direct contact with the bushing 22 b and a portion of the terminal 18 b protrudes from the bushing 22 b . Figure 7 An example weld according to the principles of the present disclosure is shown. The terminal 18 and the bushing 22 may be welded to form welds 40, 42. More specifically, the weld Figure 5 The terminal 18a and bushing 22a are shown to form a weld 40. Similarly, welding Figure 6 The terminal 18b and bushing 22b are shown to form weld 42. In some embodiments, weld 40 is associated with the battery cell 14, and weld 42 is associated with the terminal of the battery 10. Once welds 40, 42 are completed, the terminal 18 and bushing 22 are welded to each other. Furthermore, after the welding has been completed, at least a portion of the terminal 18 is integrated with bushing 22. In some embodiments, once weld 40 is completed, welds 40, 42 are sealed to the first cover 20, for example, such that the interior space defined by the first cover 20 and the housing 12 (e.g., including the battery cell 14) is sealed. In some other embodiments, the terminal 18 and bushing 22 are welded to form welds 40, 42 of a single, unitary construction that is sealed to the first cover 20. Either weld 40, 42 can be a first weld or a button weld.

[0060] Figure 8 Shown Figure 7 A view of an example weld 40 is shown. The weld 40 extends from the first cover 20. That is, a portion of the weld 40 extends from the first cover 20 and is accessible and / or exposed to receive other components to which the weld 40 can be additionally coupled (welded). Figure 9 Shown Figure 8 FIG. 4 is a cross-sectional view of an example weld 40 of FIG. 5 . The weld 40 is in physical contact with and / or coupled to the first cover 20 . Further, the weld 40 includes at least a portion that is electrically coupled to the terminal 18 a of one or more battery cells 14 .

[0061] Figure 10 Shown Figure 7 A view of an example weld 42 is shown. The weld 42 extends from the first cover 20. That is, a portion of the weld 42 extends from the first cover 20 and is accessible and / or exposed to receive other components to which the weld 42 can be additionally coupled (welded). Figure 11 Shown Figure 10 FIG2 is a cross-sectional view of an example weld 42. The weld 42 is in physical contact with and / or coupled to the first cover 20. Further, the weld 42 includes at least a portion of the post 18b that is electrically coupled to one or more battery cells 14 and / or the terminal.

[0062] Figure 12 An example of a plurality of leads 50 (eg, six leads) is shown. Figure 13 A lead assembly 24 (eg, including a plurality of leads 50) is shown. Figure 12 and Figure 13, each lead 50 may include one or more of the following: a first end 52 and a second end 56 opposite the first end 52. The first end 52 may be a lead ring and include a terminal connector 54 (e.g., a spoke) coupled to the first end 52. The second end 56 may be configured as a lead BMS connector (e.g., pins, spacing, etc.). The first end 52 (e.g., a ring that may include a terminal connector 54) may be arranged to physically and / or electrically connect the lead 50 to the terminal 18 and / or the bushing 22. The second end 56 (e.g., a BMS connector) may be arranged to extend from another portion of the lead 50 and / or bend to a predetermined angle, and / or physically and / or electrically connect to the BMS 26 (and / or any of its components). The lead 50 may be made of any material including a conductive material, for example, to conduct electricity and / or propagate signals. In a non-limiting example, the lead 50 may refer to a stamped frame and / or be made of at least one of copper, brass, steel, aluminum, titanium, platinum, etc. Further, the lead 50 can include a coating and / or finish, such as a finish using copper, nickel, tin, palladium, silver, gold, zinc, etc. The lead 50 can be used by the BMS 26 to measure / determine one or more parameters associated with the terminal 18 and / or the corresponding battery cell 14. The parameters may include, but are not limited to, voltage, current, temperature, pressure, etc., and may be associated with any component of the battery 10 (e.g., terminal 18, battery cell 14, etc.). The lead 50 (e.g., a stamped lead) can be included in a lead assembly 24 (e.g., an overmolded assembly). The lead assembly 24 may include a lead frame 25. Further, the lead assembly 24 may include one or more openings that are arranged to couple the lead assembly 24 to the first cover 20.

[0063] Any portion of each lead 50 can be articulated and / or adapted to be flexible and / or adjustable, for example, to connect the lead 50 to a terminal 18 that may be located in a different plane than the plane corresponding to another portion of the lead assembly 24. The battery 10 terminal and / or corresponding terminal 18 may be located in a different plane than the plane in which other terminals 18 (e.g., miniature terminals) are located. In other words, it is contemplated that the terminal and terminal 18 need not be coplanar relative to the top surface of the battery housing 12. In a non-limiting example, the lead assembly 24 includes an arm 58 that can be arranged to adjust the position of a portion of the lead assembly 24, for example, a portion corresponding to a predetermined terminal 18, such as a portion including a first end 52 (e.g., a ring) for a positive terminal terminal that is not coplanar with other first ends 52 (e.g., a ring) in the lead assembly 24 and / or a terminal connector 54. In some embodiments, the arm 58 can be pivotable to allow for adjustment. By making the arm 58 adjustable, the lead assembly 24 can be arranged to fit one or more terminals with different positions. Further, the size of the first end 52 (which may include the terminal connector 54) can be determined based on the terminal type and / or any other parameter. In a non-limiting example, the first end 52 and / or the terminal connector 54 can be made thicker and / or have a larger diameter than the other first ends 52 and / or terminal connectors 54 of the lead assembly 24, for example, to fit the size and type of the terminal for a positive terminal with a larger size and current rating. In a non-limiting example, the first end 52 and / or the terminal connector 54 can be made thinner and / or have a smaller diameter than the other first ends 52 and / or terminal connectors 54 of the lead assembly 24, for example, to fit the size and type of miniature terminals for receiving / transmitting / measuring battery parameters. The lead assembly 24 can be made by molding a polymer (e.g., to make the lead frame 25) onto the lead 50, thereby providing a structure for the lead 50. The lead assembly 24 may be rigid or flexible, or a combination thereof, depending on the desired design.

[0064] Figure 14 Another example embodiment of a plurality of leads 50 is shown (e.g., without first ends 52 of terminal connectors 54). In this non-limiting example, first ends 52 are arranged to receive and contact a portion of any of welds 40, 42. Further, first ends 52 may be welded to any of welds 40, 42. Figure 15 Another example of a lead assembly 24 is shown that includes a lead frame 25, a first end 52, leads 50, arms 58, and an opening 60. The opening 60 can be arranged to provide access to a portion of the plurality of leads 50 that interconnects the leads 50. The opening 60 can be used to disconnect the interconnections between the leads, thereby electrically isolating each lead 50 from the remaining leads 50.

[0065] Figure 16 An example lead assembly 24 and welds 70, 72 according to the principles of the present disclosure are shown. The lead assembly 24 includes one or more leads 50 having a first end 52 (e.g., Figures 12 to 15 ) and a second end 56 connected to the first end 52. Either of the first end 52 (and / or the terminal connector 54) is arranged to be physically and / or electrically coupled to one of the welds 40, 42 (including the terminal 18 and / or the bushing 22), as shown. Figures 7 to 11 , as shown in one or the other of . Second welds 70, 72 may be performed to weld the first end 52 of each lead 50 to the corresponding first weld 40, 42. The lead assembly 24 may be further coupled to the first cover 20 via one or more fasteners. The lead assembly 24 may be connected to the BMS 26 (e.g., via the second end 56, such as a BMS connector), wherein the BMS 26 is configured to measure at least one parameter of the battery 10, such as the voltage of the battery cell 14, via the terminal 18, the bushing 22, the lead assembly 24, the welds 40, 42, 70, 72, the first end 52, the terminal connector 54, the second end 56, etc. Any one of the welds 70, 72 may be referred to as a second weld.

[0066] Figures 17 to 20 An example of another weld (e.g., a second weld) according to the principles of the present disclosure is shown. More specifically, Figure 17 A weld 40 is shown including the terminal 18 and the bushing 22, wherein the terminal 18 is welded to the bushing 22. Any of the weld 40, the terminal 18, and the bushing 22 may be coupled to the first cover 20. The first end 52 of the lead assembly 24 is positioned over the weld 40 (e.g., in preparation for forming the second weld 70). Figure 18 A weld 70 is shown that includes weld 40 (shown in phantom) and first end 52 of lead 50. At least a portion of weld 40 is distributed around and over first end 52 of lead 50 to electrically couple first end 52 of lead 50 to terminal 18 and bushing 22. In some embodiments, weld 70 is formed after first end 52 is coupled (e.g., welded) to weld 40. Figure 19 A weld 42 is shown including the terminal 18 and the bushing 22, wherein the terminal 18 is welded to the bushing 22. Any of the weld 42, the terminal 18, and the bushing 22 may be coupled to the first cover 20. The first end 52 of the lead assembly 24 is positioned over the weld 42 (e.g., in preparation for forming the second weld 72). Figure 20A weld 72 is shown that includes weld 42 (shown in phantom) and first end 52 of another lead 50. At least a portion of weld 40 is distributed around and over first end 52 of lead 50 to electrically couple first end 52 of lead 50 to terminal 18 and bushing 22. In some embodiments, weld 72 is formed after first end 52 is coupled (e.g., welded) to weld 42.

[0067] In a non-limiting example, the first end 52 is first placed on top of the weld 40 and in contact with the weld. Welds 70 are then formed by redistributing at least some material (e.g., of the weld 40) around and over the corresponding first end 52. Further, after the first end 52 is coupled (e.g., welded) to the weld 42, welds 72 are formed. In another non-limiting example, the first end 52 is first placed on top of the weld 42 and in contact with the weld. Welds 72 are then formed by redistributing at least some material (e.g., of the weld 42) around and over the first end 52. The welds 70, 72 can physically and / or electrically couple the first end 52 to the corresponding battery cell 14, such as via the terminal 18 and bushing 22. In some embodiments, the connection between the first end 52 and the welds 40, 42, 70, 72 can be referred to as a sensing connection, a lead assembly connection, or a lead connection, any of which can be associated with sensing or measuring a battery parameter.

[0068] Figure 21 A flow chart of an example lead connection process (i.e., method) according to the principles of the present disclosure is shown. The method is for connecting a terminal connector 54 of a lead assembly 24. The method includes: inserting (block S100) a terminal 18 through a bushing 22, wherein at least a portion of the terminal 18 protrudes from the bushing 22; and performing (block S102) a first weld by welding the terminal 18 to the bushing 22. The weld is applied to at least the portion of the terminal 18 that protrudes from the bushing 22. Further, the method includes performing (block S104) a second weld by welding the first weld to the terminal connector 54. The terminal connector 54 is on the first weld, and at least a portion of the first weld is distributed around and above the terminal connector 54. The second weld electrically couples the terminal connector 54 to the bushing 22 and the terminal 18.

[0069] In some embodiments, a method for connecting leads (e.g., voltage sensing leads) of a lead assembly 24 to a first weld. Each lead may include a terminal connector 54 that can be coupled to a terminal 18 and / or a bushing 22 and / or a first weld. In some embodiments, the first weld may be a lead (Pb) button burn produced using tungsten inert gas (TIG) welding. In some other embodiments, the first weld is made to a diameter that is smaller than the diameter of the second weld. In an embodiment, the method includes performing a second weld, wherein the terminal connector 54 is added around the first weld. Performing the second weld may include redistributing the lead (Pb) material around and above the terminal connector 54.

[0070] Figure 22 A flow chart illustrating another example lead connection process (i.e., method) is shown. A method for implementing a method for coupling a first end 52 of a lead 50 to a terminal 18 and a bushing 22 of a battery 10 is described. The battery 10 includes a cover 20. The bushing 22 is coupled to the cover 20. The method includes inserting (block S106) the terminal 18 through the bushing 22, wherein at least a portion of the terminal 18 protrudes from the bushing 22 and the cover 20; and performing (block S108) a first weld 40, 42 by welding the terminal 18 to the bushing 22. The weld is applied to at least the portion of the terminal 18 protruding from the bushing 22. The method also includes performing (block S110) a second weld 70 by welding the first weld 40, 42 to the first end 52 of the lead 50. At least another portion of the first weld 40, 42 is distributed around and above the first end 52 of the lead 50.

[0071] In some embodiments, performing the first weld 40 , 42 includes forming a weld button that extends away from the cover 20 .

[0072] In some other embodiments, the welding button includes a first portion and a second portion adjacent to the first portion. The second portion is a curved structure.

[0073] In some embodiments, the method further includes positioning a first end 52 of the lead 50 between the first portion and the second portion, and coupling the first end 52 to the terminal 18 and the bushing 22 .

[0074] In some other embodiments, the first welds 40 , 42 have a third portion covering the terminal 18 .

[0075] In some embodiments, the method further includes integrating the first welds 40 , 42 and the second weld 70 into a single unitary construction.

[0076] In some other embodiments, the first end 52 of the lead 50 is a ring and is coupled to a terminal connector 54 .

[0077] In some embodiments, battery 10 further includes a battery management system (BMS) 26, which can be configured to measure battery parameters via the first end of lead 50, first welds 40, 42, and second weld 70. Lead 50 further includes a second end opposite the first end, and the method further includes coupling the second end of lead 50 to BMS 26.

[0078] The disclosure provided herein advantageously provides an arrangement for providing individual battery cells 14 within a battery 10 with individual terminals (e.g., terminals 18) to facilitate the ability to monitor each individual battery cell 14 of the battery 10, such as by coupling a lead frame to the terminals 18 to allow electrical connectivity from each battery cell 14 (via the corresponding terminals 18) to a battery management system (BMS) 26. Further, embodiments of the present disclosure are beneficial at least because heat sinking or damage to the first weld caused by conventional welding is avoided.

[0079] Those skilled in the art will appreciate that the present embodiments may not be limited to what may have been specifically shown and described. In addition, unless otherwise noted above, it should be noted that all of the accompanying drawings 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 lead connection for coupling a first end (52) of a lead (50) to a terminal (18) and a bushing (22) of a battery (10), the lead connection comprising: a first weld (40, 42) comprising the bushing (22) and the terminal (18) welded to the bushing (22); as well as A second weld (70, 72) includes the first weld (40, 42) and the first end (52) of the lead (50), at least a portion of the first weld (40, 42) being disposed around and over the first end (52) of the lead (50) to electrically couple the first end (52) of the lead (50) to the bushing (22) and the terminal (18).

2. The wire connection according to claim 1, wherein: The first weld (40, 42) is a weld button extending from the terminal (18).

3. The wire connection according to claim 2, wherein: The welding button includes a first portion and a second portion adjacent to the first portion, wherein the second portion is a bent structure.

4. The wire connection according to claim 3, wherein: A first end (52) of the lead (50) is positioned between the first portion and the second portion and is physically coupled to the terminal (18).

5. The wire connection according to any one of claims 1 to 4, wherein: The first weld (40, 42) has a third portion covering the terminal (18) and in physical contact with the terminal (18).

6. The wire connection according to any one of claims 1 to 5, wherein: The first weld (40, 42) and the second weld (70, 72) are integrated into a unitary structure.

7. The wire connection according to any one of claims 1 to 6, wherein: The first end (52) of the lead (50) is ring and is coupled to a terminal connector (54).

8. The wire connection according to any one of claims 1 to 7, wherein: The first weld (40, 42) and the second weld (70, 72) can be electrically connected to a battery cell (14) via the terminal (18), and the lead (50) can be connected to a battery management system (BMS) (26), which can be configured to measure battery parameters via the lead connection.

9. A battery (10), comprising: a housing (12) for accommodating a plurality of battery cells (14); a plurality of terminals (18), each terminal (18) of the plurality of terminals (18) being electrically coupled to at least one battery cell (14) of the plurality of battery cells (14); a cover (20) sealed to the housing (12) and including a plurality of bushings (22) coupled to the cover (20), each of the plurality of terminal posts (18) being inserted through a corresponding bushing (22); and A plurality of leads (50), the plurality of leads comprising a plurality of lead connections, each lead (50) comprising a first end (52) and a second end opposite the first end (52), each lead connection of the plurality of lead connections comprising: a first weld (40, 42) comprising one bushing (22) of the plurality of bushings (22) and one terminal (18) of the plurality of terminals (18), the one terminal (18) being welded to the one bushing (22); and A second weld (70, 72) includes the first weld (40, 42) and the first end (52) of the lead (50), at least a portion of the first weld (40, 42) being disposed around and over the first end (52) of the lead (50) to electrically couple the first end (52) of the lead (50) to the bushing (22) and the terminal (18).

10. The battery (10) according to claim 9, wherein The cover (20) sealed to the housing (12) defines a housing interior space for accommodating the plurality of battery cells (14), and each lead is connected to the outside of the housing interior space.

11. The battery (10) according to any one of claims 9 and 10, wherein The battery (10) further comprises: A battery management system (BMS) (26) is configured to measure a battery parameter via each of the plurality of lead connections, the BMS (26) being electrically coupled to the second end of each lead (50).

12. The battery (10) according to any one of claims 9 to 11, wherein The first weld (40, 42) is a weld button extending away from the cover (20).

13. The battery (10) according to claim 12, wherein The welding button includes a first portion and a second portion adjacent to the first portion, wherein the first portion is adjacent to the cover (20) and the second portion is a bent structure.

14. The battery (10) according to any one of claims 9 to 13, wherein The first weld (40, 42) has a third portion covering the one terminal (18) and in physical contact with the one terminal (18).

15. The battery (10) according to any one of claims 9 to 14, wherein The first weld (40, 42) and the second weld (70, 72) are integrated into a single unitary construction.

16. The battery (10) according to any one of claims 9 to 15, wherein The first end (52) of the lead (50) is a ring and is coupled to a terminal connector (54).

17. A method for coupling a first end (52) of a lead (50) to a terminal (18) and a bushing (22) of a battery (10), the battery (10) including a cover (20), the bushing (22) coupled to the cover (20), the method comprising: inserting (S106) the terminal (18) through the bushing (22), with at least a portion of the terminal (18) protruding from the bushing (22) and the cover (20); performing (S108) a first weld (40, 42) by welding the terminal (18) to the bushing (22), the weld being applied to at least the portion of the terminal (18) that protrudes from the bushing (22); as well as A second weld (70, 72) is performed (S110) by welding the first weld (40, 42) to the first end (52) of the lead (50), at least another portion of the first weld (40, 42) being distributed around and above the first end (52) of the lead (50).

18. The method of claim 17, wherein: Performing the first weld (40, 42) includes: A weld button is formed extending away from the cover (20).

19. The method of claim 18, wherein: The welding button includes a first portion and a second portion adjacent to the first portion, wherein the second portion is a bent structure.

20. The method of claim 19, wherein: The method further comprises: positioning a first end (52) of the lead (50) between the first portion and the second portion; and The first end (52) is coupled to the terminal (18) and the bushing (22).

21. The method according to any one of claims 17 to 20, wherein The first weld (40, 42) has a third portion covering the terminal (18).

22. The method of any one of claims 17 to 21, wherein The method further comprises: The first weld (40, 42) and the second weld (70, 72) are integrated into a single unitary construction.

23. The method of any one of claims 17 to 22, wherein The first end (52) of the lead (50) is ring and is coupled to a terminal connector (54).

24. The method of any one of claims 17 to 23, wherein The battery (10) further includes a battery management system (BMS) (26) configured to measure battery parameters via a first end (52) of the lead (50), the first weld (40, 42), and the second weld (70, 72), the lead (50) further including a second end opposite the first end (52), and the method further comprising: The second end of the lead wire (50) is coupled to the BMS (26).

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